Composite shaped abrasive particles and method of forming same

ABSTRACT

A method of forming a shaped abrasive particle includes forming a first mixture and a second mixture in a single forming process into an integral precursor shaped abrasive particle, wherein the first mixture has a different composition than a composition of the second mixture.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority from U.S. Provisional PatentApplication No. 61/581,831, filed Dec. 30, 2011, entitled “COMPOSITESHAPED ABRASIVE PARTICLES AND METHOD OF FORMING SAME,” naming inventorDoruk O. Yener et al., which application is incorporated by referenceherein in its entirety.

BACKGROUND

1. Field of the Disclosure

The following is directed to shaped abrasive particles, and moreparticularly, to composite shaped abrasive particles having certainfeatures and methods of forming such composite shaped abrasiveparticles.

2. Description of the Related Art

Abrasive articles incorporating abrasive particles are useful forvarious material removal operations including grinding, finishing,polishing, and the like. Depending upon the type of abrasive material,such abrasive particles can be useful in shaping or grinding variousmaterials in the manufacturing of goods. Certain types of abrasiveparticles have been formulated to date that have particular geometries,such as triangular shaped abrasive particles and abrasive articlesincorporating such objects. See, for example, U.S. Pat. Nos. 5,201,916;5,366,523; and 5,984,988.

Previously, three basic technologies that have been employed to produceabrasive particles having a specified shape, which are fusion,sintering, and chemical ceramic. In the fusion process, abrasiveparticles can be shaped by a chill roll, the face of which may or maynot be engraved, a mold into which molten material is poured, or a heatsink material immersed in an aluminum oxide melt. See, for example, U.S.Pat. No. 3,377,660. In sintering processes, abrasive particles can beformed from refractory powders having a particle size of up to 10micrometers in diameter. Binders can be added to the powders along witha lubricant and a suitable solvent to form a mixture that can be shapedinto platelets or rods of various lengths and diameters. See, forexample, U.S. Pat. No. 3,079,242. Chemical ceramic technology involvesconverting a colloidal dispersion or hydrosol (sometimes called a sol)to a gel or any other physical state that restrains the mobility of thecomponents, drying, and firing to obtain a ceramic material. See, forexample, U.S. Pat. Nos. 4,744,802 and 4,848,041.

The industry continues to demand improved abrasive materials andabrasive articles.

SUMMARY

In one aspect, a particulate material includes a shaped abrasiveparticle having a body comprising a first layer including a centralregion including the geometric center of the body having a first dopantconcentration (D_(1c)) and a second layer overlying the first layer, thesecond layer including a peripheral region including an external surfaceof the body spaced apart from the geometric center having a seconddopant concentration (D_(2c)), and wherein the body has a dopantconcentration difference (ΔD_(c)) between the first dopant concentrationand the second dopant concentration of at least about 0.2 wt %.

In another aspect, a shaped abrasive particle includes a body having afirst layer including having a first dopant concentration (D1 c), asecond layer overlying the first layer and having a second dopantconcentration (D2 c), and wherein the first layer and the second layerdiffer in composition by at least one dopant material selected from thegroup of elements consisting Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y,La, Zr, Hf, Ce, Pr, V, Nb, Ta, Mn, Fe, and a combination thereof.

According to another aspect, a method of forming a shaped abrasiveparticle includes forming a first mixture and a second mixture in asingle forming process into an integral precursor shaped abrasiveparticle, wherein the first mixture has a different composition than acomposition of the second mixture.

In yet another aspect, a method of forming a shaped abrasive particleincludes extruding a first mixture from a first die through an openingin a first screen and extruding a second mixture from a second diethrough the opening in a second screen to form a composite precursorshaped abrasive particle comprising the first mixture and secondmixture, wherein the first mixture has a composition different than acomposition of the second mixture.

For still another aspect, a coated abrasive article includes a substrateand a shaped abrasive particle overlying the substrate having a bodycomprising a first portion including a central region including thegeometric center of the body having a first dopant concentration(D_(1c)) and a second portion comprising a peripheral region includingan external surface of the body spaced apart from the geometric centerhaving a second dopant concentration (D_(2c)), wherein the bodycomprises a dopant concentration difference (ΔD_(c)) between the firstdopant concentration and the second dopant concentration.

According to another aspect, a particulate material includes a shapedabrasive particle having a body comprising a first layer, a second layeroverlying the first layer and comprising a second dopant, and whereinfirst layer and second layer are arranged in a stepped configurationwith respect to each other.

For another aspect, a particulate material includes a shaped abrasiveparticle having a body comprising, a first layer, a second layeroverlying the first layer and comprising a second dopant, and adiffusion interface disposed between the first layer and the secondlayer.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 includes a schematic of a system for forming a particulatematerial in accordance with an embodiment.

FIG. 2 includes a schematic of a portion of the system for forming aparticulate material in accordance with an embodiment.

FIG. 3 includes an illustration of a form after sectioning in accordancewith an embodiment.

FIG. 4A includes an illustration of a system for forming a particulatematerial in accordance with an embodiment.

FIG. 4B includes an illustration of a portion of the system used informing the particulate material in accordance with an embodiment.

FIG. 5 includes an illustration of a portion of a system used forforming a particulate material in accordance with an embodiment.

FIG. 6A includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment.

FIG. 6B includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment.

FIG. 7 includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment.

FIG. 8 includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment.

FIGS. 9-12 include cross-sectional illustrations of portions of shapedabrasive particles in accordance with an embodiment.

FIG. 13 includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment.

FIG. 14A includes a perspective view illustration of a particulatematerial in accordance with an embodiment.

FIGS. 14B and 14C include cross-sectional illustrations of a portion ofthe shaped abrasive particle of FIG. 13A.

FIGS. 15-17 include illustrations of shaped abrasive particles accordingto embodiments.

FIG. 18 includes a coated abrasive including shaped abrasive particlesaccording to an embodiment.

FIG. 19 includes a bonded abrasive including shaped abrasive particlesaccording to an embodiment.

FIG. 20A includes a perspective view of a shaped abrasive particleaccording to an embodiment.

FIG. 20B includes a perspective view of a shaped abrasive particleaccording to an embodiment.

FIG. 21 includes a perspective view illustration of a shaped abrasiveparticle according to an embodiment.

FIG. 22 includes an image of a shaped abrasive particle according to anembodiment.

FIGS. 23A and 23B include images of shaped abrasive particles havinglayers according to an embodiment.

DETAILED DESCRIPTION

The following is directed to methods of forming shaped abrasiveparticles and features of such shaped abrasive particles. The shapedabrasive particles may be used in various abrasive articles, includingfor example bonded abrasive articles, coated abrasive articles, and thelike. Alternatively, the shaped abrasive particles of the embodimentsherein may be utilized in free abrasive technologies, including forexample grinding and/or polishing slurries.

FIG. 1 includes a schematic of a system 100 used for forming aparticulate material in accordance with an embodiment. Notably, thesystem 100 may be used in the formation of composite precursor shapedabrasive particles. It will be appreciated that the formation ofcomposite precursor shaped abrasive particles may facilitate theformation of composite shaped abrasive particles.

As illustrated, the system 100 can include a belt 109 which may betranslated in a direction of 110 under a die 103. In particularinstances, the die 103 can include a first reservoir 171 configured tocontain a first mixture 101, and a second reservoir 172 separate fromthe first reservoir 171 and configured to contain a second mixture 180.In particular, the mixture 101 can be a gel formed of a ceramic powdermaterial and a liquid, wherein the gel can be characterized as ashape-stable material having the ability to hold a given shape even inthe green (i.e., unfired) state. In accordance with an embodiment, thegel can be formed of the ceramic powder material as an integratednetwork of discrete particles.

The mixture 101 can be formed to have a particular content of solidmaterial, such as a ceramic powder material. For example, in oneembodiment, the mixture 101 can have a solids content of at least about25 wt %, such as at least about 35 wt %, or even at least about 42 wt %for the total weight of the mixture 101. Still, in at least onenon-limiting embodiment, the solid content of the mixture 101 can be notgreater than about 75 wt %, such as not greater than about 70 wt %, notgreater than about 65 wt %, or even not greater than about 55 wt %. Itwill be appreciated that the content of the solids materials in themixture 101 can be within a range between any of the minimum and maximumpercentages noted above.

According to one embodiment, the ceramic powder material can include anoxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, anda combination thereof. In particular instances, the ceramic material caninclude alumina. More specifically, the ceramic material may include aboehmite material, which may be a precursor of alpha alumina. The term“boehmite” is generally used herein to denote alumina hydrates includingmineral boehmite, typically being Al2O3.H2O and having a water contenton the order of 15%, as well as psuedoboehmite, having a water contenthigher than 15%, such as 20-38% by weight. It is noted that boehmite(including psuedoboehmite) has a particular and identifiable crystalstructure, and accordingly unique X-ray diffraction pattern, and assuch, is distinguished from other aluminous materials including otherhydrated aluminas such as ATH (aluminum trihydroxide) a common precursormaterial used herein for the fabrication of boehmite particulatematerials.

Furthermore, the mixture 101 can be formed to have a particular contentof liquid material. Some suitable liquids may include organic materials,such as water. In accordance with one embodiment, the mixture 101 can beformed to have a liquid content less than the solids content of themixture 101. In more particular instances, the mixture 101 can have aliquid content of at least about 25 wt % for the total weight of themixture 101. In other instances, the amount of liquid within the mixture101 can be greater, such as at least about 35 wt %, at least about 45 wt%, at least about 50 wt %, or even at least about 58 wt %. Still, in atleast one non-limiting embodiment, the liquid content of the mixture canbe not greater than about 75 wt %, such as not greater than about 70 wt%, not greater than about 65 wt %, not greater than about 60 wt %, oreven not greater than about 65 wt %. It will be appreciated that thecontent of the liquid in the mixture 101 can be within a range betweenany of the minimum and maximum percentages noted above.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 101 can have aparticular storage modulus. For example, the mixture 101 can have astorage modulus of at least about 1×10⁴ Pa, such as at least about 4×10⁴Pa, or even at least about 5×10⁴ Pa. However, in at least onenon-limiting embodiment, the mixture 101 may have a storage modulus ofnot greater than about 1×10⁷ Pa, such as not greater than about 1×10⁶Pa. It will be appreciated that the storage modulus of the mixture 101can be within a range between any of the minimum and maximum valuesnoted above. The storage modulus can be measured via a parallel platesystem using ARES or AR-G2 rotational rheometers, with Peltier platetemperature control systems. For testing, the mixture 101 can beextruded within a gap between two plates that are set to beapproximately 8 mm apart from each other. After extruding the get intothe gap, the distance between the two plates defining the gap is reducedto 2 mm until the mixture 101 completely fills the gap between theplates. After wiping away excess mixture, the gap is decreased by 0.1 mmand the test is initiated. The test is an oscillation strain sweep testconducted with instrument settings of a strain range between 01% to100%, at 6.28 rad/s (1 Hz), using 25-mm parallel plate and recording 10points per decade. Within 1 hour after the test completes, lower the gapagain by 0.1 mm and repeat the test. The test can be repeated at least 6times. The first test may differ from the second and third tests. Onlythe results from the second and third tests for each specimen should bereported. The viscosity can be calculated by dividing the storagemodulus value by 6.28 s-1.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 101 can have aparticular viscosity. For example, the mixture 101 can have a viscosityof at least about 4×10³ Pa s, at least about 5×10³ Pa s, at least about6×10³ Pa s, at least about 8×10³ Pa s, at least about 10×10³ Pa s, atleast about 20×10³ Pa s, at least about 30×10³ Pa s, at least about40×10³ Pa s, at least about 50×10³ Pa s, at least about 60×10³ Pa s, oreven at least about 65×10³ Pa s. In at least one non-limitingembodiment, the mixture 101 may have a viscosity of not greater thanabout 1×10⁶ Pa s, not greater than about 5×10⁵ Pa s, not greater thanabout 3×10⁵ Pa s, or even not greater than about 2×10⁵ Pa s. It will beappreciated that the viscosity of the mixture 101 can be within a rangebetween any of the minimum and maximum values noted above.

Moreover, the mixture 101 can be formed to have a particular content oforganic materials, including for example, organic additives that can bedistinct from the liquid, to facilitate processing and formation ofshaped abrasive particles according to the embodiments herein. Somesuitable organic additives can include stabilizers, binders, such asfructose, sucrose, lactose, glucose, UV curable resins, and the like.

Notably, the embodiments herein may utilize a mixture 101 that isdistinct from slurries used in conventional tape casting operations. Forexample, the content of organic materials within the mixture 101,particularly, any of the organic additives noted above may be a minoramount as compared to other components within the mixture 101. In atleast one embodiment, the mixture 101 can be formed to have not greaterthan about 30 wt % organic material for the total weight of the mixture101. In other instances, the amount of organic materials may be less,such as not greater than about 15 wt %, not greater than about 10 wt %,or even not greater than about 5 wt %. Still, in at least onenon-limiting embodiment, the amount of organic materials within themixture 101 can be at least about 0.5 wt % for the total weight of themixture 101. It will be appreciated that the amount of organic materialsin the mixture 101 can be within a range between any of the minimum andmaximum values noted above.

Moreover, the mixture 101 can be formed to have a particular content ofacid or base distinct from the liquid, to facilitate processing andformation of shaped abrasive particles according to the embodimentsherein. Some suitable acids or bases can include nitric acid, sulfuricacid, citric acid, chloric acid, tartaric acid, phosphoric acid,ammonium nitrate, ammonium citrate. According to one particularembodiment, the mixture 101 can have a pH of less than about 5, and moreparticularly, within a range between about 2 and about 4, using a nitricacid additive.

Notably, the second mixture 180 can be a gel having any of the samecharacteristics of the first mixture 101, including for example, storagemodulus, amount of solid material, amount of liquid material, and amountof organic material. Still, in particular instances, the second mixture180 can have at least one feature that is different from the firstmixture 101. In particular instances, the first mixture 101 and secondmixture 180 can have different compositions, wherein at least oneelement between the two mixtures is different. For example, the firstmixture 101 may contain a dopant material that is not present in thesecond mixture 180. Alternatively, the second mixture 180 can have adopant material that is absent in the first mixture 101.

In yet another embodiment, the first mixture 101 can be different fromthe second mixture 180 on the basis of content of components within themixture. For example, one of the mixtures can contain an amount of anadditive, such as a binder, pore former, fibrous materials, and the likethat is different than the amount of said additive in the other mixture.In another embodiment, the first mixture 101 may contain a differentamount of solid material, such as a ceramic powder material, as comparedto the second mixture 180. In still other embodiments, the first mixture101 can contain a different amount of liquid material as compared to theamount of liquid material in the second mixture 180. Moreover, the firstmixture 101 may have different properties, such as storage modulus, ascompared to the second mixture 180.

As further illustrated, the die 103 can be formed such that the firstmixture 101 can be contained within the reservoir 171 separate from thereservoir 172. The first mixture 101 can be extruded in a direction 191through a die opening 105 onto the belt 109 underlying the die opening105. In fact, the first mixture 101 may be extruded directly on to thebelt 109 after exiting the die 103 through the die opening 105. As such,in particular instances, the system 100 can be used to facilitateextruding the first mixture 101 onto the belt 109 to form a first formthat can be translated along the belt 109 in the direction 110.

In accordance with an embodiment, the die opening 105 can have arectangular shape. Furthermore, the mixture 101 extruded through the dieopening 105 can have essentially the same cross-sectional shape as thedie opening 105. As such, for certain embodiments, the mixture 101 maybe extruded as a form. Reference herein to a form is a general referenceto any shaped ceramic body. The form can have various shapes andcontours depending upon the shape desired and the method of forming. Inthe illustrated embodiment, the process can include extruding a formhaving the shape of a sheet 111. The sheet 111 can have a generallyrectangular cross-sectional shape as viewed in a plane defined by athickness (t) and width (w) of the sheet 111.

Extrusion of the first material 101 can be facilitated by applying aforce 190 (or a pressure) on the mixture 101 to facilitate extruding themixture 101 through the die opening 105. In accordance with anembodiment, a particular pressure may be utilized during extrusion. Forexample, the pressure can be at least about 10 kPa, such as at leastabout 500 kPa. Still, in at least one non-limiting embodiment, thepressure utilized during extrusion can be not greater than about 4 MPa.It will be appreciated that the pressure used to extrude the mixture 101can be within a range between any of the minimum and maximum valuesnoted above.

As further illustrated, the system 100 can include extrusion of thesecond material 180 from the reservoir 172 in the direction 175 througha die opening 173. Notably, the die opening 173 can be spaced apart fromand distinct from the die opening 105. It will be appreciated thatextrusion of the second material 180 from the second reservoir 172 maybe facilitated by the application of a pressure in a direction 180. Incertain instances, the force used to extrude the second mixture 180 maybe essentially the same as the force used to extrude the first material101 from the reservoir 171. Still, in other instances, the force used toextrude the second mixture 180 from the reservoir 172 may be differentthan the force used to extrude the first material 101 from the reservoir171.

In accordance with an embodiment, the process can include the formationof a composite sheet 111 wherein the system 100 can include theformation of a first sheet 181 and the formation of a second sheet 182overlying the first sheet 181. In certain instances, the first sheet 181may be underlying the second sheet 182, and more particularly, the firstsheet 181 may be in direct contact with the second sheet 182.Furthermore, it will be appreciated that while the composite sheet 111is illustrated as being formed from a first sheet 181 and a second sheet182, additional mixtures or material may be formed to add more portionsor layers to the composite sheet 111.

In particular instances, the system 100 can be characterized as aco-extrusion process, wherein the first mixture 101 and the secondmixture 180 are extruded simultaneously on the translating belt 109 tofacilitate the formation of the composite sheet 111. Furthermore, whilesystem 100 has illustrated a particular arrangement between the firstdie opening 105 and second die opening 173, alternative arrangements ofdies may be utilized. For example, in other embodiments the die openings105 and 173 may be arranged in a coaxial relationship with respect toeach other. In still other embodiments, the die openings 105 and 173 maybe arranged in a laterally adjacent orientation, such that the dieopenings are side-by-side in a dimension of the width of the sheet 111.Moreover, it will be appreciated that the system 100 may use differentdies, wherein each die opening is associated with a distinct andseparate die.

Also, while the system 100 has illustrated a die 103 include two dieopenings 105 and 173, other dies may include additional die openingsassociated with additional reservoirs. For example, the die 103 maycontain a third reservoir configured to contain a third mixture. Thethird mixture may be different as compared to the first mixture 101 orthe second mixture 171. Moreover, the third mixture may be co-extrudedwith the first and second mixture to facilitate the formation of acomposite extrudate form including the first mixture 101, second mixture171, and third mixture.

In some embodiments, the belt 109 can be translated while extruding themixture 101 through the die opening 105. As illustrated in the system100, the mixture 101 may be extruded in a direction 191. The directionof translation 110 of the belt 109 can be angled relative to thedirection of extrusion 191 of the mixture. While the angle between thedirection of translation 110 and the direction of extrusion 191 areillustrated as substantially orthogonal in the system 100, other anglesare contemplated, including for example, an acute angle or an obtuseangle. Moreover, while the mixture 101 is illustrated as being extrudedin a direction 191, which is angled relative to the direction oftranslation 110 of the belt 109, in an alternative embodiment, the belt109 and mixture 101 may be extruded in substantially the same direction.

The belt 109 may be translated at a particular rate to facilitateprocessing. For example, the belt 109 may be translated at a rate of atleast about 3 cm/s. In other embodiments, the rate of translation of thebelt 109 may be greater, such as at least about 4 cm/s, at least about 6cm/s, at least about 8 cm/s, or even at least about 10 cm/s. Still, inat least one non-limiting embodiment, the belt 109 may be translated ina direction 110 at a rate of not greater than about 5 m/s, not greaterthan about 1 m/s, or even not greater than about 0.5 m/s. It will beappreciated that the screen 151 may be translated at a rate within arange between any of the minimum and maximum values noted above.

For certain processes according to embodiments herein, the rate oftranslation of the belt 109 as compared to the rate of extrusion of themixture 101 in the direction 191 may be controlled to facilitate properprocessing. For example, the rate of translation of the belt 109 can beessentially the same as the rate of extrusion to ensure formation of asuitable sheet 111.

After the mixture 101 is extruded through the die opening 105, themixture 101 may be translated along the belt 109 under a knife edge 107attached to a surface of the die 103. The knife edge 107 may facilitateforming a sheet 111. The sheet 111 can have particular dimensions,including for example a length (l), a width (w), and a thickness (t). Inaccordance with an embodiment, the sheet 111 may have a length thatextends in the direction of the translating belt 109, which can begreater than the width, wherein the width of the sheet 111 is adimension extending in a direction perpendicular to the length of thebelt 109 and to the length of the sheet. The sheet 111 can have athickness 184, wherein the length and width are greater than thethickness 184 of the sheet 111. According to one embodiment, the sheet111 can have a length (l), a width (w), and a height (h), wherein thelength>width>height. Moreover, the sheet 111 can have a secondary aspectratio of length:height of at least about 10, such as at least about 100,at least about 1000, or even at least about 1000.

Notably, the thickness 184 of the sheet 111 can be the dimensionextending vertically from the surface of the belt 109. In accordancewith an embodiment, the sheet 111 can be formed to have a particulardimension of thickness 184, wherein the thickness may be an averagethickness of the sheet 111 derived from multiple measurements. Forexample, the thickness 184 of the sheet 111 can be at least about 0.1mm, such as at least about 0.5 mm. In other instances, the thickness 184of the sheet 111 can be greater, such as at least about 0.8 mm, at leastabout 1 mm, at least about 1.2 mm, at least about 1.6 mm, or even atleast about 2 mm. Still, in one non-limiting embodiment, the thickness184 of the sheet 111 may be not greater than about 10 mm, not greaterthan about 5 mm, or even not greater than about 2 mm. It will beappreciated that the sheet 111 may have an average thickness within arange between any of the minimum and maximum values noted above.

After extruding the mixture 101 from the die 103, the sheet 111 may betranslated in a direction 112 along the surface of the belt 109.Translation of the sheet 111 along the belt 109 may facilitate furtherprocessing to form precursor shaped abrasive particles. For example, thesheet 111 may undergo a shaping process within the shaping zone 113. Inparticular instances, the process of shaping can include shaping asurface of the sheet 111, including for example, an upper major surface117 of the sheet 111. In other embodiments, other major surfaces of thesheet may undergo shaping, including for example, the bottom surface orside surfaces. For certain processes, shaping can include altering acontour of the sheet through one or more processes, such as, embossing,rolling, cutting, engraving, patterning, stretching, twisting, and acombination thereof.

In one particular embodiment, the process of shaping can include forminga feature 119 in the upper major surface 117 of the sheet 111. Moreparticularly, a shaping structure 115 may be contacted to the uppermajor surface 117 of the sheet 111 facilitating the formation of afeature 119 or a pattern of features in the upper major surface 117. Itwill be appreciated that the shaping structure 115 can take variousforms, including for example, a roller having various features on itssurface, wherein such features may be imparted to the upper majorsurface 117 of the sheet 111 upon contact between the shaping structure115 and the upper major surface 117.

Still, it will be appreciated that alternative shaping structures andmethods of shaping a sheet may be utilized. For example, the surface ofthe belt 109 may be textured such that features of the texture areimparted to the sheet 111, and the finally-formed shaped abrasiveparticles. Moreover, various devices may be used to impart a feature orpattern of features on the side surfaces of the sheet 111.

In accordance with an embodiment, the process of forming a shapedabrasive particle can further include translation of the sheet 111 alongthe belt 109 through a forming zone 121. In accordance with anembodiment, the process of forming a shaped abrasive particle caninclude sectioning the sheet 111 to form precursor shaped abrasiveparticles 123. For example, in certain instances, forming can includeperforating a portion of the sheet 111. In other instances, the processof forming can include patterning the sheet 111 to form a patternedsheet and extracting shapes from the patterned sheet.

Particular processes of forming can include cutting, pressing, punching,crushing, rolling, twisting, bending, drying, and a combination thereof.In one embodiment, the process of forming can include sectioning of thesheet 111. Sectioning of the sheet 111 can include the use of at leastone mechanical object, which may be in the form of a gas, liquid, orsolid material. The process of sectioning can include at least one or acombination of cutting, pressing, punching, crushing, rolling, twisting,bending, and drying. Moreover, it will be appreciated that sectioningcan include perforating or creating a partial opening through a portionof the sheet 111, which may not extend through the entire height of thesheet 111. For example, sectioning can include a water jet cuttingprocess. In another embodiment, sectioning of the sheet 111 can includeuse of a mechanical object including one or a plurality of a blade, awire, a disc, and a combination thereof. The blades may be orientedrelative to each other in a variety of configurations to achieve thedesired sectioning. For example, the blades may be arranged parallel toeach other, such as in a gang configuration. Alternatively, themechanical object may include a set of spiral blades connected to eachother or independent of each other.

Alternatively, the process of forming shaped abrasive particles caninclude the use of radiation to section the sheet 111 into discreteprecursor shaped abrasive particles. For example, use of radiation mayinclude the use of a laser to score or otherwise cut discrete shapedabrasive particles from the sheet 111.

It will be appreciated that at least one blade may be translated throughthe sheet 111 to facilitate sectioning. In particular instances, asectioning process using a blade can include translating a blade inmultiple directions including a first direction, and a second directiondifferent than the first direction through the sheet 111. More notably,certain sectioning processes may utilize a plurality of blades that canbe translated across and through the sheet 111 in multiple directions tofacilitate the formation of precursor shaped abrasive particles 123.

In certain instances, the method of sectioning can include maintainingan opening or perforation formed in the sheet 111. Maintaining theopening after sectioning the sheet 111 by a mechanical object mayfacilitate suitable formation of shaped abrasive particles and featuresof shaped abrasive particles and features of a batch of shaped abrasiveparticles. Maintaining the opening can include at least partially dryingat least one surface of the sheet 111 defining the opening. The processof at least partially drying can include directing a drying material atthe opening. A drying material may include a liquid, a solid, or even agas. According to one particular embodiment, the drying material caninclude air. Furthermore, the process of maintaining the opening caninclude selectively directing a drying material, such as a gas, at theopening and limiting the impingement of gas on other surfaces of thesheet 111 substantially spaced apart from the opening.

In certain instances, the process of sectioning can be conducted priorto sufficient drying of the sheet. For example, sectioning can beconducted prior to volatilization of not greater than about 20% of theliquid from the sheet 111 as compared to the original liquid content ofthe sheet during initial formation of the sheet 111. In otherembodiments, the amount of volatilization allowed to occur before orduring sectioning can be less, such as, not greater than about 15%, notgreater than about 12%, not greater than about 10%, not greater thanabout 8%, or even not greater than about 4% of the original liquidcontent of the sheet.

As indicated by the description of embodiments herein, sectioning can beconducted simultaneously with the process of forming. Moreover,sectioning can be conducted continuously during the process of forming.Sectioning may not necessarily include a change in composition to thesheet, such as in the case of ablation processes, which rely uponvaporization.

According to one embodiment, sectioning can be conducted at particularconditions to facilitate the forming process. For example, sectioningcan be conducted at controlled sectioning conditions including at leastone of a controlled humidity, a controlled temperature, a controlled airpressure, a controlled air flow, a controlled environmental gascomposition, and a combination thereof. Control of such conditions mayfacilitate control of the drying of the sheet and facilitate formationof shaped abrasive particles having particular features. According to aparticular embodiment, sectioning can include monitoring and control ofone or more certain environmental conditions, including but not limitedto humidity, temperature, air pressure, air flow, environmental gascomposition, and a combination thereof.

For at least one embodiment, the temperature of the environment used forsectioning (i.e., sectioning temperature) that can be controlledrelative to the temperature of the environment used in other processes.For example, the sectioning temperature can be conducted at asubstantially different temperature as compared to the temperature usedduring forming (e.g., extruding) of the sheet. Alternatively, thetemperature used during forming of the sheet can be substantially thesame as the sectioning temperature. Moreover, in another embodiment, themechanical object can have a temperature greater than a temperature ofthe sheet 111 during sectioning. In an alternative condition, themechanical object can have a temperature less than a temperature of thesheet 111.

For another aspect, the process of sectioning can include providing atleast one opening agent to an opening formed in the sheet 111 aftersectioning, wherein the opening agent is sufficient to maintain anopening in the sheet after sectioning. Some suitable methods ofproviding the opening agent can include depositing, coating, spraying,printing, rolling, transferring, and a combination thereof. In oneparticular embodiment, the mechanical object can be coated with a leastone opening agent, wherein the opening agent can be transferred from asurface of the mechanical object to a surface of the sheet defining theopening. The opening agent can include a material selected from thegroup of inorganic materials, organic materials, polymers, and acombination thereof. In one embodiment, the opening agent may be afoaming agent, surfactant, and a combination thereof.

FIG. 2 includes an illustration of a particular device that may beutilized within the forming zone 121 to facilitate sectioning. Asillustrated, the process of sectioning may include the use of a cuttingdevice 201 having a plurality of blades 202, 203, 204, 205, and 206arranged in parallel to each other. The cutting device 201 can betranslated in multiple directions through the sheet 111 to facilitatethe formation of precursor shaped abrasive particles 123. For example,as illustrated in FIG. 2, the cutting device 201 may be translated firstin a direction 207 angled with respect to the length (l) of the sheet111. Thereafter, the cutting device 201 may be translated in a seconddirection 209 different that the first direction 207 and angled withrespect to the first direction 207. Finally, the cutting device 201 maybe translated across and through the sheet 111 in a third direction 208that is different than the first direction 207 or second direction 209to facilitate the formation of precursor shaped abrasive particles.While reference herein has noted that a single cutting device 201 may betranslated in multiple directions, it will be appreciated thatindividual cutting devices may be utilized for discrete and individualcutting directions.

The process of sectioning can create different types of shaped abrasiveparticles in a single sectioning process. Different types of shapedabrasive particles can be formed from the same processes of theembodiments herein. Different types of shaped abrasive particles includea first type of shaped abrasive particle having a first two-dimensionalshape versus a second type of shaped abrasive particle having adifferent two-dimensional shape. Furthermore, different types of shapedabrasive particles may differ from each other in size. For example,different types of shaped abrasive particles may have different volumesas compared to each other. A single process which is capable of formingdifferent types of shaped abrasive particles may be particularly suitedfor producing certain types of abrasive articles.

As further illustrated, upon sectioning of the sheet 111 with a cuttingdevice 201, a plurality of precursor shaped abrasive particles may beformed in the sheet 111. In particular instances, as illustrated in FIG.2, a first type of precursor shaped abrasive particles 240 can be formedfrom the sheet 111. The precursor shaped abrasive particles 240 may havea generally triangular shape two-dimensional shape as viewed in a planedefined by the length (l) and width (w) of the sheet 111.

Furthermore, the sectioning process may form another type of precursorshaped abrasive particles 243 approximate to, and at, the edge of thesheet 111. The precursor shaped abrasive particles 243 can have atriangular two-dimensional shape as viewed in a plane defined by thelength (l) and width (w) of the sheet 111. However, the precursor shapedabrasive particles 243 can be smaller in size as compared to theprecursor shaped abrasive particles 240. In particular instances, theprecursor shaped abrasive particles 243 can have a volume that is notgreater than about 95% of the volume of the precursor shaped abrasiveparticles 240. Volume may be an average value calculated by themeasurement of volume for at least 20 shaped abrasive particles of thesame type. In other instances, the precursor shaped abrasive particles243 can have a volume that is not greater than about 92%, not greaterthan about 90%, not greater than about 85%, such as not greater thanabout 80%, not greater than about 75%, not greater than about 60%, oreven not greater than about 50% of the volume of the precursor shapedabrasive particles 240. Still, in one non-limiting embodiment, theprecursor shaped abrasive particles 243 can have a volume that is atleast about 10%, such as at least about 20%, at least about 30%, or evenat least about 40% of the volume of the precursor shaped abrasiveparticles 240. The difference in volume between the precursor shapedabrasive particles 243 and precursor shaped abrasive particles 240 canbe within a range between any of the minimum and maximum percentagesnoted above.

Another type of precursor shaped abrasive particles 242 may be formed inthe same sectioning process used to form the precursor shaped abrasiveparticles 240 and 243 from the sheet 111. Notably, the precursor shapedabrasive particles 242 can have a quadrilateral two-dimensional shape asviewed in a plane defined by the width (w) and length (l) of the sheet111. According to one particular embodiment, the precursor shapedabrasive particles 242 may have a two-dimensional shape of aparallelogram. It will be appreciated that the precursor shaped abrasiveparticles 242 can have a difference in volume as compared to the otherprecursor shaped abrasive particles as described in other embodimentsherein.

The sectioning process may create another type of shaped abrasiveparticle 244 used to form the precursor shaped abrasive particles 240,242, and 243 from the same sheet 111. Notably, the precursor shapedabrasive particles 244 can have a different two-dimensional polygonalshape as compared to the precursor shaped abrasive particles 240, 242,or 243. As illustrated in the embodiment of FIG. 2, the precursor shapedabrasive particles 244 can have a quadrilateral shape, and moreparticularly, a trapezoidal shape, as viewed in a plane defined by thewidth (w) and length (1) of the sheet 111. It will be appreciated thatthe precursor shaped abrasive particles 244 can have a difference involume as compared to the other precursor shaped abrasive particles asdescribed in other embodiments herein.

FIG. 3 includes an illustration of a portion of a sheet 111 after asectioning process in accordance with an embodiment. Notably, the sheet111 can be cut in a first direction 308, and subsequently cut in asecond direction 307 at an angle relative to the first direction 308.The sectioning process can create precursor shaped abrasive particles321 having a generally quadrilateral polygonal shape as viewed in theplane defined by the length and width of the sheet 111. Furthermore,depending upon the sectioning process, a different type of precursorshaped abrasive particles 322 can be created in the same sectioningprocess used to create the precursor shaped abrasive particles 321.Notably, the precursor shaped abrasive particles 322 can be a differentas compared to the precursor shaped abrasive particles 321 in terms oftwo-dimensional shape, size, and a combination thereof. For example, theprecursor shaped abrasive particles 322 can have a greater volume ascompared to the precursor shaped abrasive particles 321.

Referring again to FIG. 1, after forming precursor shaped abrasiveparticles 123, the particles may be translated through a post-formingzone 125. Various processes may be conducted in the post-forming zone125, including for example, heating, curing, vibration, impregnation,doping, and a combination thereof.

In one embodiment, the post-forming zone 125 includes a heating process,wherein the precursor shaped abrasive particles 123 may be dried. Dryingmay include removal of a particular content of material, includingvolatiles, such as water. In accordance with an embodiment, the dryingprocess can be conducted at a drying temperature of not greater thanabout 300° C., such as not greater than about 280° C., or even notgreater than about 250° C. Still, in one non-limiting embodiment, thedrying process may be conducted at a drying temperature of at leastabout 50° C. It will be appreciated that the drying temperature may bewithin a range between any of the minimum and maximum temperatures notedabove.

Furthermore, the precursor shaped abrasive particles 123 may betranslated through a post-forming zone at a particular rate, such as atleast about 0.2 feet/min and not greater than about 8 feet/min.

Furthermore, the drying process may be conducted for a particularduration. For example, the drying process may be not greater than aboutsix hours.

After the precursor shaped abrasive particles 123 are translated throughthe post-forming zone 125, the particles may be removed from the belt109. The precursor shaped abrasive particles 123 may be collected in abin 127 for further processing.

In accordance with an embodiment, the process of forming shaped abrasiveparticles may further comprise a sintering process. For certainprocesses, sintering can be conducted after collecting the precursorshaped abrasive particles 123 from the belt 109. Alternatively, thesintering may be a process that is conducted while the precursor shapedabrasive particles 123 are on the belt. Sintering of the precursorshaped abrasive particles 123 may be utilized to densify the particles,which are generally in a green state. In a particular instance, thesintering process can facilitate the formation of a high-temperaturephase of the ceramic material. For example, in one embodiment, theprecursor shaped abrasive particles 123 may be sintered such that ahigh-temperature phase of alumina, such as alpha alumina is formed. Inone instance, a shaped abrasive particle can comprise at least about 90wt % alpha alumina for the total weight of the particle. In otherinstances, the content of alpha alumina may be greater, such that theshaped abrasive particle may consist essentially of alpha alumina.

While the system 100 has been illustrated as having a certainarrangement of processes associate with certain zones, it will beappreciated that such processes can be completed in different orders.Moreover, while certain processes have been described as associate withcertain zones through which the belt 109 traverses, the processes do notnecessarily need to be implemented in a conveyor assembly manner asillustrated. Any of the processes herein may be completed separate fromthe system 100.

FIG. 4A includes a schematic of a system that may be used in theformation of composite precursor shaped abrasive particles in accordancewith another embodiment. In particular instances, the system 400 may bereferred to generally as a screen printing process for forming compositeprecursor shaped abrasive particles. In accordance with an embodiment,the system 400 can include a screen 451 configured to be translated in adirection 453 and having openings 452 configured to receive materialextruded from the die 403 as the screen 451 passes underneath. Asfurther illustrated, the system 400 can include a belt 409 configured tobe translated in direction 410 and travel underneath the die 403 withinthe application zone 465. The system 400 can include a die 403 includingmultiple reservoirs for the delivery of different mixtures into theopenings 452 of the screen 451 facilitating the formation of compositeprecursor shaped abrasive particles. Notably, in the printing process,the material can be extruded from the die 403 and through opening 452 inthe screen and onto the belt 409.

In accordance with an embodiment, the die 403 can include a reservoir411 configured to contain a first mixture 401. As further illustrated,the mixture 401 may be placed under a force (or pressure) to facilitateextrusion of the first mixture 401 in a direction 491 through the dieopening 407. The first mixture 401 can have any characteristics of anymixtures described in the embodiments herein. In a particular instance,the reservoir 411 can be defined as a volume between a first wall 431and a second wall 432.

As further illustrated, the die 403 can include a second reservoir 412configured to contain a second mixture 402 within the volume definedbetween a wall 432 and a wall 433. In particular instances, the secondmixture 402 may be extruded from the reservoir 412 in a direction 492through the die opening 408 by applying a force (or pressure) to thesecond mixture 402. The second mixture 402 can have any characteristicsof any mixtures described in the embodiments herein. Notably, the secondmixture 402 can be different than or the same as the first mixture 401.

As further illustrated, the die 403 may include a reservoir 413 definedas a volume between wall 433 and wall 434. In accordance with anembodiment, the third mixture 405 may be extruded from the reservoir 413by applying a force (or pressure) to the third mixture 405 and extrudingthe third mixture 405 in a direction 493 through the die opening 419.The third mixture 403 can have any characteristics of any mixturesdescribed in the embodiments herein. Notably, the third mixture 403 canbe different than or the same as the first mixture 401. Moreover, thethird mixture 403 can be different than or the same as the secondmixture 402.

During operation, the die can be operated such that the first mixture401 can be extruded through the first die opening 407 and onto thescreen 451. In particular instances, at least a portion of the firstmixture 401 may be extruded into the openings 452 of the screen 451, andmore particularly, through the openings 452 of the screen 451 and ontothe belt 409. Furthermore, during operation, the second mixture 402 maybe extruded from the reservoir 412 onto the screen 451. In particularinstances, at least a portion of the second material 402 extruded fromthe die opening 408 and onto the screen 451 may fill the openings 452within the screen. Notably, the process may be conducted such that thefirst material 401 and second material 402 are extruded simultaneouslythrough respective die openings 407 and 408.

Furthermore, during operation, the third material 405 may be extrudedfrom the reservoir 413 and through the die opening 493 onto the screen451. In particular instances, the third material 405 may be extrudedthrough the die opening 419 and onto the screen 451, such that theopenings 452 are at least partially filled with the third material 405.

As will be appreciated, the system can be utilized such that at leastthe first mixture 401 and second mixture 402 may be simultaneouslyextruded into the openings 452 of the screen 451. Furthermore, it willbe appreciated that while the die 403 is illustrated as havingindividual reservoirs 411, 412, and 413 that are longitudinallydisplaced from each other, other arrangements between reservoirs and dieopenings are contemplated. For example, in an alternative embodiment thefirst die opening 407 and second die opening 408 may be coaxiallyarranged with respect to each other. Furthermore, a third die opening,such as die opening 419 may also be arranged coaxially with respect tothe first die opening 407 and second die opening 408.

Referring briefly to FIG. 4B, a portion of a screen 451 is illustrated.As shown, the screen 451 can include an opening 452, and moreparticularly, a plurality of openings 452 extending through the volumeof the screen 451. In accordance with an embodiment, the openings 452can have a two-dimensional shape as viewed in a plane defined by thelength (l) and width (w) of the screen that include various shapes, forexample, polygons, ellipsoids, numerals, Greek alphabet letters, Latinalphabet letters, Russian alphabet characters, complex shapes includinga combination of polygonal shapes, and a combination thereof. Inparticular instances, the openings 452 may have two-dimensionalpolygonal shapes such as, a triangle, a rectangle, a quadrilateral, apentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and acombination thereof.

After forcing the mixtures 401, 402, and 403 through their respectivedie openings 407, 408, and 419 and through the openings 452 in thescreen 451, precursor shaped abrasive particles 423 may be printed onthe belt 409 disposed under the screen 451. According to a particularembodiment, the precursor shaped abrasive particles 423 can have a shapesubstantially replicating the shape of the openings 452, and at least atwo-dimensional shape substantially replicating the shape of theopenings 452 as viewed in a plane defined by the length and width of thescreen. Notably, the mixtures 401, 402, and 403 can be combined in theopenings 452 and forced through the screen in rapid fashion, such thatthe average residence time of the mixtures 401, 402, and 403 within theopenings 452 can be less than about 2 minutes, less than about 1 minute,less than about 40 second, or even less than about 20 seconds. In onenon-limiting embodiment, the mixtures 401, 402, and 403 may besubstantially unaltered during printing as they travel through thescreen openings 452, and more particularly, may experience noappreciable loss of volatile materials or drying in the openings 452 ofthe screen 451.

During operation, the screen 451 can be translated in a direction 453while the belt 409 can be translated in a direction 410 substantiallysimilar to the direction 423 to facilitate a continuous printingoperation. As such, the precursor shaped abrasive particles 423 may beprinted onto the belt 409 and translated along the belt 409 to undergofurther processing. It will be appreciated that further processing caninclude processes described in the embodiments herein, including forexample, shaping, applying a dopant material, drying, sintering, and thelike. In fact, as illustrated, the precursor shaped abrasive particles423 may be translated through a shaping zone 113, wherein at least oneexterior surface of the precursor shaped abrasive particles 423 may beshaped as described in embodiments herein. The precursor shaped abrasiveparticles 423 may be translated through an application zone 131, whereina dopant material can be applied to at least one exterior surface of theparticles. And further, the precursor shaped abrasive particles 423 maybe translated on the belt 409 through a post-forming zone 425, wherein avariety of processes, including for example, drying, may be conducted onthe precursor shaped abrasive particles 423 as described in embodimentsherein.

While certain foregoing embodiments have described a screen printingprocess using a screen, it will be appreciated that such screen printingprocesses may utilize multiple screens. For example, one screen printingprocess for the formation of composite shaped abrasive particles caninclude the use of a first screen, which is completely or partiallyfilled with a first mixture, and provision of a second screen, which canbe different than the first screen, and provision of a second mixturewithin the openings of the second screen. The second screen can beplaced over the first screen or over precursor shaped abrasive particlesformed from the first screen. The second mixture can be provided on theprecursor shaped abrasive particles of the first mixture to formcomposite precursor shaped abrasive particles. It will be appreciatedthat the first screen and second screen can have, but need notnecessarily utilize, different size openings, different two-dimensionalshapes of openings, and a combination thereof.

Moreover, in certain instances, the first screen and second screen canbe used at the same time as a composite screen to shape the first andsecond mixtures. Still, the first screen and second screen may be usedin separate processes. For example, wherein the first mixture isprovided in the first screen at a first time and the second mixture isprovided in the second screen at a second time. As noted above the firsttime and second time may be simultaneous with each other, such as whenthe first screen and second screen are used at the same time to shapethe first and second mixtures. Still, the first time and the second timemay be different, such that the first mixture can be provided in theopenings of the first screen first, and after the first mixture has beenformed in the openings of the first screen, the second mixture can beprovided on the first mixture. The second screen can be oriented on thefirst screen to facilitate alignment between the openings in the firstscreen and openings in the second screens to facilitate suitabledelivery of the second mixture onto the first mixture contained in theopenings of the first screen. Still, in an alternative embodiment, thefirst mixture may be first removed from the openings of the first screento create precursor shaped abrasive particles of the first mixture.Thereafter, the precursor shaped abrasive particles of the first mixturecan be oriented with respect to openings of the second screen, and thesecond mixture can be placed in the openings of the second screen andonto the precursor shaped abrasive particles of the first mixture tofacilitate formation of composite precursor shaped abrasive particlesincluding the first mixture and the second mixture.

FIG. 5 includes an illustration of a portion of a system for formingcomposite precursor shaped abrasive particles in accordance with anembodiment. Notably the die 503 can include a series of die openingsthat are arranged coaxially with respect to each other. For example, thedie 503 can include a first reservoir 511 surrounding a second reservoir512. In one embodiment, the reservoir 511 can be defined by an annulardie opening 507. As further illustrated, the reservoir 512 can bedefined between walls 532 and 533, configured to contain a secondmixture 402 and be extruded in a direction 593 through a die opening508. The die opening 508 can be disposed within the center of theannular die opening 507 of the first reservoir 511. The arrangement ofdie openings 507 and 508 with respect to each other may facilitate theformation of a particular type of composite precursor shaped abrasiveparticle which will be described in further embodiments herein. Notably,the die 503 represents an alternative arrangement of die openings 507and 508 that may be used to deliver different mixtures in differentarrangements to facilitate the formation of composite shaped abrasiveparticles having a particular arrangement of different materials withinthe body.

The processes of embodiments herein may incorporate the use of one ormore dopant precursors that may facilitate the formation of dopants inthe finally-formed shaped abrasive particles. A dopant precursor can bea material that has a first morphology and/or composition that isaltered by one or more processes to form a corresponding dopant having amorphology or composition that is different than the dopant precursor.Moreover, a particular manner of providing the dopant precursor mayfacilitate particular placement and concentration of the correspondingdopant in the finally-formed shaped abrasive particle.

In certain aspects, one or more dopant precursors may be incorporatedinto one or more mixtures. Some suitable examples of dopant precursorscan include organic materials, which may be in the form of compounds orcomplexing, including but not limited to, polymers. Moreover, some othersuitable dopant precursors can include inorganic materials, such ascompounds of oxides, carbides, nitrides, borides, oxycarbides,oxynitrides, salt compounds, and a combination thereof.

In one embodiment, one of the mixtures of the embodiments herein mayinclude a dopant precursor that can be a discrete phase of materialwithin the mixture. For example, the dopant precursor can be in the formof a particulate material, including but not limited to, a colloidalmixture.

The dopant precursor particulate material may also have a certainaverage particles size, including for example, an average particle sizeconfigured to form a dopant material in the shaped abrasive particlehaving an average size less than an average grain size of the shapedabrasive particle. In one particular embodiment, the dopant precursorparticulate material can have an average particle size of not greaterthan about 200 microns, such as not greater than about 150 microns, notgreater than about 100 microns, not greater than about 80 microns, notgreater than about 50 microns, not greater than about 20 microns, oreven not greater than about 10 microns. Still, in another non-limitingembodiment, the dopant precursor particulate material can have anaverage particle size of at least about 1 nm, such as at least about 10nm, at least about 100 nm, or even at least about 500 nm. It will beappreciated that the dopant precursor particulate material can have anaverage particle size within a range between any of the minimum andmaximum values noted above.

Alternatively, the dopant precursor may be in solution with the mixture,such as in the form of a solid solution. Some dopant precursors in theform of salts may be added to the mixture and form a solid solution withthe phase of the mixture, as opposed to being a distinct phase.

It will be appreciated that a plurality of dopant precursors may be usedin any combination. Additionally, more than one dopant precursor may beused with respect to one or more mixtures of the embodiments herein. Inparticular instances, different mixtures may include different contentsof the same dopant precursor. Moreover, different mixtures may includedifferent dopant precursors.

A shaped abrasive particle of an embodiment herein can have a bodydefined by a length (l), which can be the longest dimension of any sideof the shaped abrasive particle, a width (w) defined as a longestdimension of the shaped abrasive particle through a midpoint of theshaped abrasive particle, and a thickness (t) defined as the shortestdimension of the shaped abrasive particle extending in a directionperpendicular to the length and width. In specific instances, the lengthcan be greater than or equal to the width. Moreover, the width can begreater than or equal to the thickness.

Additionally, the body of the shaped abrasive particles can haveparticular two-dimensional shapes. For example, the body can have atwo-dimensional shape as viewed in a plane define by the length andwidth having a polygonal shape, ellipsoidal shape, a numeral, a Greekalphabet character, Latin alphabet character, Russian alphabetcharacter, complex shapes utilizing a combination of polygonal shapesand a combination thereof. Particular polygonal shapes includetriangular, rectangular, quadrilateral, pentagon, hexagon, heptagon,octagon, nonagon, decagon, any combination thereof.

The body of a shaped abrasive particle can be made of a ceramicmaterial, including for example, an oxide, a nitride, a carbide, aboride, an oxycarbide, an oxynitride, and a combination thereof. Inparticular instances, the body can include alumina. More specifically,the body can consist essentially of alpha alumina.

FIG. 6A includes a perspective view illustration of a composite shapedabrasive particle in accordance with an embodiment. As illustrated, thecomposite shaped abrasive particle 600 can have a body 601 including anupper major surface 602 and a bottom major surface 603 opposite theupper major surface 602. The upper major surface 602 and the bottommajor surface 603 can be separated from each other by side surfaces 606,605, and 604. As illustrated, the body 601 of the shaped abrasiveparticle 600 can have a triangular two-dimensional shape as viewed in aplane of the upper major surface 602 defined by the length and width ofthe body 601. In particular, the body 601 can have a length (l), a width(w) extending through a midpoint 691 of the body 601, and a thickness(t). In accordance with an embodiment, the body 601 can have a primaryaspect ratio defined as a ratio of length:width. In certain instances,the primary aspect ratio of the body 601 can be at least about 1.2:1,such as at least about 1.5:1, at least about 2:1, at least about 3:1, oreven at least about 4:1. Still, the primary aspect ratio may be notgreater than about 100:1. It will be appreciated that the primary aspectratio of the body 601 may be within a range between any of the minimumand maximum ratios noted above.

Furthermore, the body 601 may have a secondary aspect ratio defined by aratio of length:thickness. In certain instances, the secondary aspectratio of the body 601 may be at least about 1.2:1, such as at leastabout 1.5:1, at least about 2:1, at least about 3:1, at least about 4:1,at least about 5:1, or even at least about 10:1. Still, in at least onenon-limiting embodiment, the body 601 can have a secondary aspect ratiothat is not greater than about 100:1. It will be appreciated that thesecondary aspect ratio may be within a range between any of the minimumand maximum ratios provided above.

Furthermore, the body 601 can have a tertiary aspect ratio defined by aratio of the width:thickness. In certain instances, the tertiary aspectratio of the body 601 may be at least about 1.2:1, such as at leastabout 1.5:1, at least about 2:1, at least about 3:1, at least about 4:1,at least about 5:1, or even at least about 10:1. Still, in at least onenon-limiting embodiment, the body 601 can have a tertiary aspect ratiothat is not greater than about 100:1. It will be appreciated that thetertiary aspect ratio may be within a range between any of the minimumand maximum ratios provided above.

The shaped abrasive particles of embodiments herein can have aparticular size, as measured by the length of the body. For example, theshaped abrasive particles may have a median particle size of not greaterthan about 5 mm. Alternatively, the median particle may be less, such asnot greater than about 4 mm, not greater than about 3 mm, not greaterthan about 2 mm, or even not greater than about 1.5 mm. In still anotheraspect, the median particle size of the shaped abrasive particles can beat least about 10 microns, at least about 100 microns, at least about200 microns, at least about 400 microns, at least about 600 microns, oreven at least about 800 microns. It will be appreciated that the medianparticle size of the shaped abrasive particles can be within a rangebetween any of the above minimum and maximum values.

The shaped abrasive particles of embodiments herein can have aparticular grain size, particularly for grains of alpha alumina. Forexample, the shaped abrasive particles may have an average grain size ofnot greater than about 500 microns, such as not greater than about 250microns, or even not greater than about 100 microns, not greater thanabout 50 microns, not greater than about 20 microns, or even not greaterthan about 1 micron. In another aspect, the average grain size can be atleast about 0.01 microns, such as at least about 0.05 microns, at leastabout 0.08 microns, or even at least about 0.1 microns. It will beappreciated that the average grain size of the shaped abrasive particlescan be within a range between any of the above minimum and maximumvalues.

In certain instances, the composite shaped abrasive particles of theembodiments herein may include different materials within differentregions of each body. More particularly, in certain instances, thecomposite shaped abrasive particles may comprise various concentrationsof dopant in different regions within the body. For example, withrespect to the composite shaped abrasive particle of FIG. 6A, the body601 can comprise a layered structure. More particularly, the body mayinclude a first layer 621, a second layer 622 underlying the first layer621, and a third layer 623 underlying the second layer 622. Inparticular instances, the first layer 621 may be formed such that itdefines a significant portion of the upper major surface 602, and moreparticularly essentially the entire surface of the upper major surface.Additionally, the third layer 623 may be formed such that it defines asignificant portion of the body, including for example, the bottom majorsurface 603. In particular instances, the body 601 can be structuredsuch that the third layer 623 forms essentially the entire area of thebottom major surface 603 of the body 601.

In particular instances, as illustrated, the body 601 can be formed suchthat the side surfaces, including 604, 605, and 606 may be formed of acombination of the first layer 621, the second layer 622, and the thirdlayer 623. It will be appreciated that each of the layers 621, 622, and623 may differ from each other in composition. In particular instances,the composition of the first layer 621 may differ from the compositionof the second layer 622 by at least one element. In more particularinstances, the composition of the first layer 621 may differ from thecomposition of the second layer 622 by the existence of a particulardopant material.

Suitable dopant materials for use in any of the layer 621, 622, or 623can include an element or compound including an alkali element, alkalineearth element, rare earth element, hafnium, zirconium, niobium,tantalum, molybdenum, vanadium, and a combination thereof. In oneparticular embodiment, the dopant material includes an element orcompound including an element such as lithium, sodium, potassium,magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum,cesium, praseodymium, niobium, hafnium, zirconium, tantalum, molybdenum,vanadium, chromium, cobalt, iron, germanium, manganese, nickel,titanium, zinc, and a combination thereof.

The body 601 can be formed such that any one of the layer 621, 622, and623 can contain a particular amount of dopant, which may be based inpart upon the dopant provided in the corresponding mixture forming thelayer, or the amount of dopant in an adjacent layer. In particularinstances, the amount of dopant within any of layers of the body 601 canbe at least about 0.2 wt %, such as least about 0.6 wt %, at least about1 wt %, at least about 1.4 wt %, at least about 1.8 wt %, at least about2 wt %, at least about 2.5 wt %, at least about 3 wt %, at least about3.5 wt %, at least about 4 wt %, or even at least about 5 wt % for thetotal amount of dopant present within the layer. Still, according to onenon-limiting embodiment, the total amount of dopant material in any ofthe layers 621, 622, and 623 can be not greater than about 30 wt %, suchas not greater than about 26 wt %, not greater than about 24 wt %, notgreater than about 20 wt %, not greater than about 18 wt %, or even notgreater than about 16 wt % for the total weight of the layer. The theamount of dopant within any one of the layers can be within a rangebetween any of the minimum and maximum percentages noted above.

In another embodiment, the difference in dopant material concentrationbetween any of the layers can be at least 5%, as defined by the equation[(C1-C2)/C1]×100%, wherein C1 is the layer of higher concentration ofdopant material and C2 is the layer of lower dopant materialconcentration. In other instances, the difference in concentration canbe greater, such as at least about 10%, at least about 20%, at leastabout 30%, at least about 40%, at least about 50%, at least about 60%,at least about 70%, at least about 80%, or even at least about 90%.Still, in other instances, the difference may be not greater than about100%, such as not greater than about 99%, not greater than about 95%,not greater than about 85%, not greater than about 75%, not greater thanabout 65%, not greater than about 55%, not greater than about 45%, notgreater than about 35%, not greater than about 25%, not greater thanabout 15%, or even not greater than about 10%. It will be appreciatedthat the difference in dopant concentration between any of the layerscan be within a range between any of the minimum and maximum percentagesnoted above.

In certain instances, the body 601 can have a central region includingthe geometric center 602 of the body 601. The central region may have aparticularly low content of dopant material relative to other portionsof the body 601, such as the exterior surfaces, such as the upper majorsurface 602 or bottom major surface 603. In certain instances, thecentral region of the body 601 can be essentially free of a dopantmaterial. According to one particular embodiment, the body 601 can beformed such that a central region of the body 601 can have a firstdopant concentration (D_(1C)) and a peripheral region of the body, whichis spaced apart from the geometric center 691 of the body 601, can havea second dopant concentration (D_(2C)). In certain instances, thecentral region of the body 601 can be in the form of a layer and spacedapart from the upper major surface 602 and the bottom major surface 603of the body 601. Still, the central region may intersect at least aportion of one of the side surfaces, such as side surface 604, 605, or606. In the particular embodiment of FIG. 6A, the central region can bedefined by the layer 622. As such, the central region can be spacedapart from the upper major surface 602 and the bottom major surface 603.Furthermore, the central region can be disposed between the peripheralregion defined by layer 621 and the peripheral region defined by 623.That is, the central region can be at least partially underlying theperipheral region 621 and partially overlying the peripheral regiondefined by layer 623.

For at least one embodiment, the peripheral region can intersect a majorsurface of the body 601 such as the upper major surface 602, the bottommajor surface 603, or the side surfaces 604, 605, or 606. It will beappreciated, that in particular instances, the peripheral region mayintersect one or a combination of exterior surfaces of the body 601. Inaccordance with the composite shaped abrasive particle 600, theperipheral region can be defined by layer 621 or layer 623. As such, theperipheral region of the body 601 can include layer 621 intersecting theupper major surface 602, and side surfaces 604, 605, and 606 of the body601. Additionally, the body 601 can have a second peripheral regiondefined by the layer 623 and intersecting the bottom major surface 603and side surfaces 604, 605, and 606 of the body 601.

In accordance with another embodiment, the central region can be formedto have a first dopant concentration that is different than the seconddopant concentration of a peripheral region within the body. In certaininstances, the first dopant concentration can be greater than the seconddopant concentration. Still in other instances, the second dopantconcentration may be greater than the first dopant concentration. Inaccordance with at least one embodiment, the body can have a firstdopant concentration that is different than a second dopantconcentration and thus defining a dopant concentration difference. Incertain instances, the dopant concentration difference can be at leastabout 0.2 wt % as measured by the difference in wt % of dopant materialfor the total weight of the body. In still other instances, the dopantconcentration difference can be greater, such as at least about 0.4 wt%, at least about 0.6 wt %, at least about 1 wt %, at least about 1.4 wt%, or even at least about 1.8 wt %. Still, the dopant concentrationdifference may be not greater than about 30 wt %, such as not greaterthan about 20 wt %, not greater than about 15 wt %, such as not greaterthan about 12 wt %, not greater than about 11 wt %, not greater thanabout 10 wt %, not greater than about 8 wt %, or even not greater thanabout 6 wt %. It will be appreciated that the dopant concentrationdifference can be within a range between any of the minimum and maximumpercentages noted above. It will further be appreciated that the totalamount of dopant in any region, such as the peripheral region or centralregion can be within a range between any of the above minimum andmaximum percentages.

FIG. 6B includes a perspective view illustration of a composite shapedabrasive particle in accordance with an embodiment. As illustrated, thecomposite shaped abrasive particle 650 can have a body 651 including anupper major surface 652 and a bottom major surface 653 opposite theupper major surface 652. The upper major surface 652 and the bottommajor surface 653 can be separated from each other by side surfaces 654,655, and 656. The body 651 of the shaped abrasive particle 650 can havea triangular two-dimensional shape as viewed in a plane of the uppermajor surface 652 defined by the length and width of the body 651. Inparticular, the body 651 can have the features of aspect ratio, medianparticle size, and grain size, as described in the embodiment herein.

In certain instances, the composite shaped abrasive particles of theembodiments herein may include different materials within differentregions of each body. More particularly, in certain instances, thecomposite shaped abrasive particles may comprise various concentrationsof dopant in different regions within the body. For any embodimentsherein, concentration can refer to weight percent or volume percent ofthe dopant material. The weight percent or volume percent can be basedon the weight or volume of the entire body, particular region, or layer.

For example, with respect to the composite shaped abrasive particle ofFIG. 6B, the body 651 can comprise a layered structure. The body mayinclude a first layer 657 and a second layer 658 underlying the firstlayer 657. In particular instances, the first layer 657 may be formedsuch that it defines a significant portion of the bottom major surface653, and more particularly, can essentially define the entire exteriorsurface of the bottom major surface 653. Additionally, in oneembodiment, the second layer 658 can defines a significant portion ofthe body 651, including for example, the upper major surface 652. Inparticular instances, the body 651 can be structured such that thesecond layer 658 forms at least a portion of the area of the upper majorsurface 652 of the body 651. In one particular embodiment, the firstlayer 657 can be in direct contact with the second layer 658.

The first layer 657 can have a substantially planar structure extendingfor the entire length and width of the body 651 and defining asubstantial portion of the exterior surfaces of the body 651.Additionally, the second layer 658 can have a substantially planarstructure extending for the entire length and width of the body 651 anddefining a substantial portion of the exterior surfaces of the body 651.

In particular instances, as illustrated, the body 651 can be formed suchthat the side surfaces, including 654, 655, and 656 may be formed of acombination of the first layer 657 and the second layer 658. Asillustrated, the body 651 can be formed such that the first layer 657can have a first thickness (t1) and the second layer 658 can have asecond thickness (t2). In particular embodiments, the first thicknessand the second thickness can be substantially the same. In still otherinstances, the first thickness and the second thickness can besubstantially different. For example, the first thickness and the secondthickness can be different from each other by at least about 5%, atleast about 10%, at least about 20%, or even at least about 30%. Still,in one non-limiting embodiment, the first thickness and the secondthickness can be different from each other by not greater than about90%, such as not greater than about 80%, not greater than about 70%, notgreater than about 50%. It will be appreciated that the difference inthickness between the first thickness and the second thickness can bewithin a range between any of the above minimum and maximum percentages.

According to one embodiment, the first thickness can be at least about5% of the average thickness of the body. In other instances, the firstthickness can be greater, such as at least about 10%, at least about20%, at least about 30%, at least about 40%, or even at least about 50.In one non-limiting embodiment, the first thickness can be not greaterthan about 99%, such as not greater than about 90%, not greater thanabout 80%, not greater than about 70%, not greater than about 60%, notgreater than about 50%, not greater than about 40%, or even not greaterthan about 30% of the average thickness of the body. It will beappreciated that the first thickness can be within a range between anyof the minimum and maximum percentages noted above. Moreover, the secondthickness can have the same attributes of the first thickness withrespect to the average thickness of the body. Also, other additionallayers, such as an intermediate layer, can have the same features.

It will be appreciated that each of the layers 657 and 658 may differfrom each other in composition. In particular instances, the compositionof the first layer 657 may differ from the composition of the secondlayer 658 by at least one element. In more particular instances, thecomposition of the first layer 657 may differ from the composition ofthe second layer 658 by at least one dopant material or even a pluralityof dopant materials.

Suitable dopant materials for use in any of the layers 657 and 658 caninclude an element or compound such as an alkali element, alkaline earthelement, rare earth element, hafnium, zirconium, niobium, tantalum,molybdenum, vanadium, or a combination thereof. In one particularembodiment, the dopant material includes an element or compoundincluding an element such as lithium, sodium, potassium, magnesium,calcium, strontium, barium, scandium, yttrium, lanthanum, cesium,praseodymium, niobium, hafnium, zirconium, tantalum, molybdenum,vanadium, chromium, cobalt, iron, germanium, manganese, nickel,titanium, zinc, and a combination thereof.

The body 651 can be formed such that any one of the layers 657 and 658can contain a different amount of dopant with respect to each other. Incertain instances, the first layer 657 can include a central region ofthe body 651 including the geometric center 602 of the body 601. Inother embodiments, the second layer 658 may include a peripheral regionof the body 651. According to one embodiment, the first layer 657 canhave can have a first dopant concentration (D_(1C)) and the second layercan have a second dopant concentration (D_(2C)). In accordance withanother embodiment, the first layer 657 can have a first dopantconcentration that is different than the second dopant concentration ofthe second layer 658 within the body. In certain instances, the firstdopant concentration can be greater than the second dopantconcentration. Still in other exemplary bodies, the second dopantconcentration may be greater than the first dopant concentration. Inaccordance with at least one embodiment, the body 651 can have a firstdopant concentration that is different than a second dopantconcentration and thus defining a dopant concentration difference (ΔDc).

In particular instances, the dopant concentration difference (ΔDc)between the two layers 657 and 658 of the body 651 can be at least about0.2 wt %, such as least about 0.6 wt %, at least about 1 wt %, at leastabout 1.4 wt %, at least about 1.8 wt %, at least about 2 wt %, at leastabout 2.5 wt %, at least about 3 wt %, at least about 3.5 wt %, at leastabout 4 wt %, or even at least about 5 wt % for the total amount ofdopant present within the body 651. Still, according to one non-limitingembodiment, the total difference in the amount of dopant materialbetween any one of the layers 657 and 658 can be not greater than about30 wt %, not greater than about 26 wt %, not greater than about 24 wt %,not greater than about 20 wt %, not greater than about 18 wt %, or evennot greater than about 16 wt % for the total weight of the body. Thedifference in the amount of dopant material between any one of thelayers can be within a range between any of the minimum and maximumpercentages noted above. As noted herein, while the foregoing weightpercentages are recited as based upon the weight of the body, it will beappreciated that the same percentages can be based upon the weight ofcorresponding layers. For example, if the first layer 657 had 5 wt % ofa dopant for the total weight of the layer and the second layer 658 had2 wt % of the same dopant for the total weight of the layer, the weightpercent difference between the two layers could be calculated as 3 wt %.

In another embodiment, the difference in dopant material concentrationbetween the layers 657 and 658 layers can be at least 5%, as defined bythe equation [(C1-C2)/C1]×100%, wherein C1 is the layer of higherconcentration of dopant material and C2 is the layer of lower dopantmaterial concentration. In other instances, the difference inconcentration can be greater, such as at least about 10%, at least about20%, at least about 30%, at least about 40%, at least about 50%, atleast about 60%, at least about 70%, at least about 80%, or even atleast about 90%. Still, in other instances, the difference may be notgreater than about 100%, such as not greater than about 99%, not greaterthan about 85%, not greater than about 75%, not greater than about 65%,not greater than about 55%, not greater than about 45%, not greater thanabout 35%, not greater than about 25%, not greater than about 15%, oreven not greater than about 10%. It will be appreciated that thedifference in dopant concentration between any of the layers can bewithin a range between any of the minimum and maximum percentages notedabove.

According to one embodiment, the second layer 658 can include a seconddopant including zirconium. More particularly, the second dopant mayinclude zirconia, and more particularly, can consist essentially ofzirconia. For certain embodiments, the second layer 658 can include agreater content of zirconia than a content of zirconia in the firstlayer 657. In another embodiment, the dopant concentration difference ofzirconia between the first layer 657 and the second layer 658 can be atleast about 0.2 wt %, such as least about 0.5 wt %, at least about 1 wt%, at least about 1.4 wt %, at least about 1.8 wt %, or even at leastabout 2 wt %. Still, according to one non-limiting embodiment, the totaldifference in the amount of dopant material between any one of thelayers 657 and 658 can be not greater than about 50 wt %, such as notgreater than about 30 wt %, not greater than about 25 wt %, not greaterthan about 20 wt %, not greater than about 15 wt %, or even not greaterthan about 12 wt % for the total weight of the body. The difference inthe amount of zirconia dopant material between the first layer 657 andthe second layer 658 can be within a range between any of the minimumand maximum percentages noted above.

According to one particular aspect, the first layer 657 can include afirst dopant that is different than a second dopant within the secondlayer 658, and more particularly, the first layer 657 may be essentiallyfree of the second dopant material present in the second layer 658.Likewise, in certain instances, the second layer 658 can be include asecond dopant that is different than a first dopant within the firstlayer 657, and more particularly, the second layer 658 may beessentially free of the first dopant material present in the first layer657.

Still, in other embodiments, a dopant may diffuse from one adjacentlayer into another during processing. In particular, controlledprocessing may facilitate the controlled diffusion of a dopant betweenlayers, such that controlled delivery of a dopant material initiallypresent in a single layer may be transmitted to one or more adjacentlayers to form a suitable composite shaped abrasive particle havingparticular contents of dopants, or even exhibit step function diffusionboundaries.

While the body 651 illustrated includes a first layer 657 having agenerally triangular two-dimensional shape and a second layer 658overlying the first layer 657 and having a substantially similartriangular two-dimensional shape, it will be appreciated that thecomposite bodies of the embodiments herein can include multiple layers,wherein each of the layers can have different two-dimensional shapeswith respect to each other. For example, as illustrated in FIG. 20A, ashaped abrasive particle can be formed to have a body 2001 including afirst layer 2002 having a first two-dimensional shape as viewed in aplane defined by a length and a width of the body 2001 and a secondlayer 2003 overlying the first layer 2002 having a secondtwo-dimensional shape. In particular, as illustrated, the first layer2002 can have a generally polygonal two-dimensional shape and the secondlayer 2003 can have a generally elliptical or circular two-dimensionalshape.

FIG. 20B includes an illustration of another embodiment including ashaped abrasive particle 2004 including a first layer 2005 having afirst two-dimensional shape and a second layer 2006 having a second twodimensional shape. FIGS. 20A and 20B are exemplary, and it will beappreciated that the shaped abrasive particles of the embodiments hereincan included a plurality of layers including a variety of differenttwo-dimensional shapes, including but not limited to polygons,ellipsoids, numerals, Greek alphabet characters, Latin alphabetcharacters, Russian alphabet characters, complex shapes having acombination of polygonal shapes, corner-truncated shapes, and acombination thereof, wherein the body comprises a polygonal shape asviewed in a plane defined by the dimension of the length and width,wherein the body comprises a polygonal shape selected from the group oftriangle, rectangle, quadrilateral, pentagon, hexagon, heptagon,octagon, nonagon, decagon, and a combination thereof. The foregoingincludes corner truncated shapes, wherein at least a portion of thefeature of a corner is missing or altered in shape, which may be aresult of certain processing techniques.

Moreover, as evident in FIGS. 20A and 20B, shaped abrasive particlesincluding a combination of layers, wherein each of the layers can havedifferent two-dimensional shapes with respect to each other and may alsohave different dimensional features for any one of the dimensions of thelayers. Provision such shaped abrasive particles may facilitatealternative or improved deployment of the particles in an abrasivearticle and may further facilitate improved performance or use of theabrasive article. For example, the two-dimensional shape of the firstlayer 2002 can have an average length (or diameter) that issignificantly different than an average length (or diameter) of thetwo-dimensional shape of the second layer 2003. Moreover, thetwo-dimensional shape of the first layer 2002 can have an average widththat is significantly different than the average width of thetwo-dimensional shape of the second layer 2003. Additionally, thetwo-dimensional shape of the first layer 2002 can have an averagethickness that is significantly different than an average thickness ofthe two-dimensional shape of the second layer 2003.

As also illustrated in FIGS. 20A and 20B, each of the layers can havedifferent areas or volumes with respect to each other. For example, theaverage area (e.g., average surface area of a major exterior surface) ofthe two-dimensional shape of the first layer 2002 can be significantlydifferent than an average area of the two-dimensional shape of thesecond layer 2003. Additionally, the average volume of thetwo-dimensional shape of the first layer 2002 can be significantlydifferent than an average volume of the two-dimensional shape of thesecond layer 2003. For example, the first layer 2002 can have a volumethat is significantly greater than the volume of the second layer 2003,such that the first layer 2002 comprises a greater volume portion of thetotal volume of the body 2001 compared to the second layer 2003. Still,in alternative embodiments, the first layer 2002 can have a volume thatis significantly less than a volume of the second layer 2003.

Referring again to FIG. 6B, the body may include a diffusion interface659 disposed between the first layer 657 and the second layer 658. Inone embodiment, the diffusion interface 659 can define a boundary of thefirst layer 657 and the second layer 658. Moreover, the diffusioninterface 659 can separate the first layer 657 and the second layer 658.According to one embodiment, the body 651 can have a diffusion interface659 defining a diffusion boundary between the first layer 657 and thesecond layer 658, wherein the concentration of at least one dopant on afirst side of the diffusion interface 659 (e.g., within the first layer657) can be significantly different than the concentration of the samedopant on the opposite side (e.g., within the second layer 658) of thediffusion interface 659. It will be appreciated that the diffusioninterface 659 can define a boundary characterizing a difference in morethan one dopant concentration between the first layer 657 and the secondlayer 658. In certain instances, the diffusion interface 659 can definea step function difference in a concentration of at least one dopantbetween the first layer 657 and the second layer 658, including forexample, a step function difference in a concentration of a seconddopant in the second layer 568 compared to a concentration of the seconddopant in the first layer 657.

The diffusion interface 659 can extend for an entire area between thefirst layer 657 and the second layer 658. In certain instances, thediffusion interface 659 can extend for an entire length of the body 651.Moreover, the diffusion interface 659 can extend for an entire width ofthe body 651. It will be appreciated that the diffusion interface 659may have a planar contour or alternatively, a curved, arcuate, orirregular contour. The shape and orientation of the diffusion interface659 may depend in part upon the shape and orientation of thecorresponding layers or portions that define the diffusion interface.

According to another aspect, a shaped abrasive particle having multipleportions, such as a first layer 657 and a second layer 658 can be formedsuch that one of the portions (or layers) can be in compression relativeto a second, adjacent portion, and the second portion can be in tensionrelative to the corresponding and adjacent portion. For example, withrespect to the shaped abrasive particle of FIG. 6B, the first layer 657may be in compression relative to the second layer 658 and the secondlayer 658 may be in tension relative to the first layer 657.Alternatively, the second layer 658 may be in compression relative tothe first layer 657.

The relative state of compression and tension in one or more portions(e.g., layers 657 and 658) of the body of a shaped abrasive particle maybe controlled by selection of at least one of the shape, dimension, andcomposition of the portions relative to each other. In particularinstances, the body of the shaped abrasive particle can be formed suchthat the difference in stress (or strain) between a first portion and asecond portion is at least about 5%, such as at least about 10%, atleast about 20%, at least about 30%, at least about 40%, at least about50%, at least about 60%, at least about 70%, at least about 80% or evenat least about 90%. Still, in another instance, the difference in stress(or strain) between a first portion and a second portion can be notgreater than about 90%, such as not greater than about 80%, not greaterthan about 70%, not greater than about 60%, such as not greater thanabout 50%, not greater than about 40%, not greater than about 30%, suchas not greater than about 20%, not greater than about 10%, or even notgreater than about 5%. It will be appreciated that the difference instress (or strain) between a first portion and a second portion in thebody can be within a range between any of the minimum and maximumpercentages noted above.

As noted herein, the body 651 may include additional portions or layers.For example, the body 651 may include at least one intermediate layerdisposed between the first layer 657 and the second layer 658. Theintermediate layer may have substantially the same composition as thefirst layer 657. Additionally, the intermediate layer may havesubstantially the same composition as the second layer 658.Alternatively, the intermediate layer can have a substantially differentcomposition as compared to the composition of the first layer, which mayinclude at least one difference in a dopant material. Likewise, theintermediate layer can have a substantially different composition ascompared to the composition of the second layer, which may include adifference of at least one dopant material.

The intermediate layer may be disposed between the first layer 657 andthe second layer 658 and define an additional diffusion interface, inaddition to the diffusion interface described above. Accordingly, thebody may have a first diffusion interface (e.g., a first intermediatediffusion interface) between the first layer and the intermediate layerand a second diffusion interface (e.g., a second intermediate diffusioninterface between the intermediate layer and the second layer 658. Allof the diffusion interfaces can have the properties of the diffusioninterfaces described in accordance with embodiments herein.

FIG. 7 includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment. The complex shaped abrasiveparticle 700 can include a body 701 having an upper major surface 702, alower major surface 703 separated from the upper major surface 702 byside surfaces 704, 705, and 706. The composite shaped abrasive particle700 represents an alternative arrangement of layers of compositematerial, and particularly a core-shell arrangement of different layerswithin the body 701. In accordance with one embodiment, the body 701 caninclude a first layer 721 intersecting the exterior side surfaces of thebody including side surfaces 704, 705, and 706. In particular instances,the first layer 721 can intersect and define the exterior side surfaces704, 705, and 706. As further illustrated, the first layer 721 candefine at least a portion of the upper major surface 702 and the lowermajor surface 703. In fact, as illustrated, the first layer 721 can havea generally annular shape, wherein the second layer 723 and third layer724 are disposed within an interior volume of the first layer 721.

As illustrated, the body can be formed such that a peripheral region, asdefined by layer 721 can surround at least a portion of another layerdefining another region, such as a central region of the compositeshaped abrasive particle. Furthermore, the body 701 can include a secondlayer 723 disposed within an interior volume of the first layer 721. Aportion of the second layer 723 may intersect the upper major surface702. Additionally, a portion of the second layer 723 may intersect thebottom major surface 703. In fact, a portion of the second layer 723 mayintersect and define a portion of the upper major surface 702 and lowermajor surface 703. Notably, the second layer 723 may be spaced apartfrom at least a portion of the exterior surface of the body, such as theexterior side surfaces 704, 705, and 706. In accordance with anembodiment, the second layer may define a central region having acomposition that may differ from the composition of the first layer 721.In particular instances, the second layer 723 may define a centralregion of the body 701 having a dopant concentration differing from adopant concentration within the first layer 721 as described in otherembodiments herein. Moreover, the second layer 723 may define anintermediate layer between the first layer 721 and a third layer 724.

As further illustrated, the composite shaped abrasive particle 700 caninclude a body including a third layer 724 disposed within a volume ofthe second layer 723 and first layer 721. The third layer 724 mayrepresent a central region and can include a geometric center of thebody 704, which represents the volumetric midpoint of the body 701. Inaccordance with an embodiment, the third layer 724 can represent acentral region that may be spaced apart from one or more exteriorsurfaces of the body, including for example the exterior side surfaces704, 705, and 706. Additionally, the third layer 724 may represent acentral region of the body 701 that can be intersecting and defining aportion of the upper major surface 702 and bottom surface 703. It willbe appreciated however that the third layer 724 may not necessarilydefine and intersect any portions of the exterior surfaces of the body701 and may be contained entirely within the interior volume spacedapart from any exterior surfaces.

In accordance with an embodiment, the body can include a central regionthat comprises a particular volume portion (volume %) of the totalvolume of the body as compared to the volume portion of a peripheralregion. For example, the body 701 may contain a central region thatcomprises a smaller volume portion of the total volume of the body ascompared to the volume portion of a peripheral region. Still, inalternative embodiments, the body 701 can be formed such that a centralregion can take up a greater volume portion of the total volume of thebody as compared to a volume portion of a peripheral region.

FIG. 8 includes a perspective view illustration of a composite shapedabrasive particle in accordance with an embodiment. As illustrated, thecomposite shaped abrasive particle 800 can include a body 801 having anupper major surface 802 and a lower major surface 803 spaced apart fromthe upper major surface 802 by side surfaces 804, 805, and 806. Whileforgoing embodiments have demonstrated peripheral regions and centralregions having generally symmetrical shapes, it will be appreciated thatalternative composite abrasive particles of the embodiments herein mayutilize peripheral regions and central regions having non-symmetricshapes. For example, as illustrated in FIG. 8, the body can include arandom arrangement of second layer portions 823 intersecting anddefining various portions of the exterior surfaces, including the uppermajor surface 802, lower major 803, and side surfaces 804, 805, and 806.Furthermore, the body 801 can include a first layer 821 that can includea geometric center 891 of the body 801.

Additionally, the first layer 821 may be intersecting and definingvarious portions of the exterior surfaces of the body 801, including forexample, the upper major surface 802, the lower major surface 803, andthe side surfaces 804, 805, and 806. In particular instances, the firstlayer 821 may define a continuous phase or matrix extending throughout amajority of the volume of the body 801, wherein the second layerportions are present as dispersed and discrete regions spaced apart fromeach other. As such, in one particular embodiment, the first layer 821may represent a central region of the body. Additionally, in certaininstances, the second layer portions 823 may define peripheral regionsof the body 801.

In accordance with an embodiment, the first layer 821 defining thecentral region of the body 801 can have a non-symmetric shape. Thenon-symmetric shape may be viewed in a plane defined by the length andwidth of the body 801, or alternatively, the width and thickness of thebody 801. Furthermore, the body 801 can include second layers portions823 defining peripheral regions, wherein the peripheral regions can havenon-symmetric shapes. In particular instances, the peripheral regions asdefined by the second layer portions 823 may have non-symmetrical shapesas viewed in a plane as defined by the length and width of the body 801or in a plain defined by the width and thickness of the body 801.

FIG. 9 includes a cross-sectional illustration of a portion of a shapedabrasive particle in accordance with an embodiment. Notably, the shapedabrasive particle can include a body 901 having a bottom surface 904, anupper major surface 902 opposite the bottom surface 904, and a sidesurface 903 joining the bottom surface 904 and upper major surface 902.As further illustrated, the body 901 can include a side surface 905opposite the side surface 903 joining the bottom surface 904 and uppermajor surface 902. In accordance with a particular embodiment, the body901 can have a curvilinear upper major surface 902. Notably, in someinstances, the upper major surface 902 can have a convex contour suchthat the thickness of the body 901 at the midpoint (t_(m)) is greaterthan the thickness at either one of the side surfaces (t_(s)) 903 or905. For some embodiments, the bottom surface 902 may be substantiallyplaner as compared to the upper major surface 902.

FIG. 10 includes a cross-sectional illustration of an alternative shapedabrasive particle in accordance with an embodiment. Notably, the shapedabrasive particle can have a body 1001 including a bottom surface 1004,an upper major surface 1002 opposite the bottom surface 1004, and sidesurfaces 1003 and 1005 opposite each other and joining the bottomsurface 1005 and upper major surface 1002. As illustrated, the body 1001can have a particularly unique contour, wherein the upper major surface1002 has a convex contour, and the bottom surface 1004 also has a convexcontour such that the thickness at the midpoint (t_(m)) is significantlygreater than the thickness of the body 1001 at the edges (t_(e)) definedby surfaces 1001 and 1005.

FIG. 11 includes a cross-sectional illustration of an alternative shapedabrasive particle in accordance with an embodiment. Notably, the shapedabrasive particle can have a body 1101 including a bottom surface 1104,an upper major surface 1102 opposite the bottom surface 1104, and sidesurfaces 1103 and 1105 opposite each other and separating the bottomsurface 1104 and upper major surface 1102. As illustrated, the body 1101can have a unique contour, wherein the upper major surface 1102 can havea concave contour and the bottom surface 1104 can have a substantiallyplanar contour such that the thickness at the midpoint (t_(m)) issignificantly less than the thickness of the body 1101 at the edges(t_(e)) defined by surfaces 1101 and 1105.

FIG. 12 includes a cross-sectional illustration of an alternative shapedabrasive particle in accordance with an embodiment. Notably, the shapedabrasive particle can have a body 1201 including a bottom surface 1204,an upper major surface 1202 opposite the bottom surface 1204, and sidesurfaces 1203 and 1205 opposite each other and separating the bottomsurface 1204 and upper major surface 1202. As illustrated, the body 1201can have a unique contour, wherein the upper major surface 1202 can havea concave contour and the bottom surface 1204 can have a concave contoursuch that the thickness at the midpoint (t_(m)) is significantly lessthan the thickness of the body 1201 at the edges (t_(e)) defined bysurfaces 1201 and 1205.

In accordance with an embodiment, the shaped abrasive particles of theembodiments herein may be formed such that at least two exteriorsurfaces have significantly different two-dimensional shapes withrespect to each other. In particular, the shaped abrasive particles canhave a bottom major surface having a two-dimensional shape that issignificantly different from a two-dimensional shape of an upper majorsurface. In more particular embodiments, the two-dimensional shapes canbe any one of the two-dimensional shapes noted in the embodimentsherein. For example, the bottom surface can be a first polygonal shapeand the upper major surface can be a different polygonal shape.

FIG. 13 includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment. The shaped abrasive particle1300 includes a body 1301 having a bottom surface 1304 and an uppersurface 1303 spaced away from the bottom surface 1304 by side surfaces1305, 1306, and 1307. As illustrated in FIG. 13, the bottom surface 1304can have a generally triangular shape, while the upper surface 1303 canhave an ellipsoidal shape.

FIG. 14A includes a perspective view illustration of a shaped abrasiveparticle in accordance with an embodiment. Notably, body 1401 can have afirst long side 1402, a second long side 1403, and a third long side1404. Furthermore, the body 1401 can include a first short side 1405coupled to the first long side 1402 and second long side 1403. The body1401 may further include a second short side 1406 coupled to the firstlong side 1402 and third long side 1404. While the body 1401 of theshaped abrasive particle may be considered to have a generally pentagonshape as viewed in a plane defined by the length and width, inparticular instances, the body 1401 can be defined as a corner truncatedtriangle, wherein the first short side 1405 and second short side 1406define flat surfaces where otherwise a corner, such as corner 1422,would exist. Notably, such corner-truncated shapes may represent asignificant portion of shaped abrasive particles in a batch, formedthrough the process described herein.

As illustrated, the body 1401 can have a first angle 1407 definedbetween the first long side 1402 and first short side 1405 as viewed atthe upper major surface 1430 of the body 1401. In accordance with anembodiment, the first angle 1407 can be greater than about 90°. In moreparticular instances, the first angle 1407 can be at least about 92°, atleast about 95°, at least about 100°, or even at least about 105°.Still, the first angle, in one non-limiting embodiment, can be notgreater than about 160°.

The body can further include a second angle 1408 formed between thefirst short side 1405 and second long side 1403 as viewed at the uppermajor surface 1430 of the body 1401. In accordance with an embodiment,the second angle 1408 can be the same as the first angle 1407. Still, inanother embodiment, the second angle 1408 can be different than thefirst angle 1407. According to one instance, the second angle 1408 canbe obtuse. Alternatively, the second angle 1408 may be greater thanabout 90°, and more particularly, at least about 92°, at least about95°, at least about 100°, or even at least about 105°. Still, the secondangle 1408, in one non-limiting embodiment, can be not greater thanabout 160°.

As further illustrated, the body 1401 of the shaped abrasive particlecan include a third angle 1409 defined as the angle between the secondshort side 1406 and first long side 1402 as viewed at the upper majorsurface 1430 of the body 1401. The third angle 1409 may be the same asthe first angle 1407 or the second angle 1408. Alternatively, the thirdangle 1409 may be different than the first angle 1407 and second angle1408.

The body 1401 can also include a fourth angle 1410 defined as the anglebetween the second short surface 1406 and third long side 1404. Thefourth angle 1410 may be different than the first angle 1407, secondangle 1408, or third angle 1409. In particular instances, the fourthangle 1410 can be less than the first angle 1407, less than the secondangle 1408, or less than the third angle 1409. In at least oneparticular embodiment, the fourth angle 1410 may be substantiallyorthogonal (90°). In yet other instances, the fourth angle 1410 may begreater than 90°.

The body 1401 may further include a fifth angle 1411 between the thirdlong side 1404 and second long side 1403 as viewed top down looking atthe upper major surface 1430 of the body 1401. Notably, the fifth angle1411 can be different than the first angle 1407, the second angle 1408,the third angle 1409, or the fourth angle 1410. In particular instances,the fifth angle 1411 can be less than the first angle 1407, less thanthe second angle 1408, less than the third angle 1409, or even less thanthe fourth angle 1410. The fifth angle 1411 can define the corner 1422of a triangle, and thus be less than about 90°, and more particularlyless than about 70°. While the body 1401 has been illustrated as havinga first short side and a second short side 1406, it will be appreciatedthat the body could incorporate a third short side separating the secondlong side and third long side 1404.

In accordance with an embodiment, the first short side 1405 can have alength that is not greater than about 60% of a length of the first longside 1402. In other embodiments, the length of the first short side 1405relative to the first long side 1402 can be less, such as not greaterthan about 50%, or not greater than about 40%, not greater than about30%, not greater than about 20%, or even not greater than about 15%.Still, the first short side 1405 can be at least about 2%, such as atleast about 5%, at least about 10%, at least about 15%, or even at leastabout 20% of the length of the first long side 1402. It will beappreciated that the length of the first short side 1405 can be within arange between any of the minimum and maximum percentages noted above.Furthermore, it will be appreciated that the length of the second shortside 1406 can have the same characteristics of the first short side 1405relative to the first long side 1402. Additionally, the length of thesecond short side 1406 may differ with respect to the length of thefirst short side 1405.

In accordance with an embodiment, the first long side 1402 can have alength (11) that is substantially equal to the length (12) of the secondlong side 1403. Still, the length (11) of the first long side 1402 maybe significantly different than the length (12) of the second long side1403. Moreover, the length (11) of the first long side 1402 may besubstantially the same as the length (13) of the third long side 1404.Alternatively, the length (11) of the first long side 1402 may besignificantly different that the length (13) of the third long side1404. Additionally, the length (12) of the second long side 1403 may besubstantially the same as the length (13) of the third long side 1404.Alternatively, the length (12) of the second long side 1403 may besignificantly different than the length (13) of the third long side1404.

FIG. 14B includes a cross-sectional illustration of a portion of theshaped abrasive particle of FIG. 14A. Notably, the cross-sectional imageis taken through the axis 1450 which is defined by a point at one corner1421 of the body 1401 and a midpoint 1441 of the body 1401. Inaccordance with a particular embodiment, the body 1401 can have agreater thickness at a midpoint 1441 of the shaped abrasive particle ascompared to the thickness of the body measured at the corner 1421. Incertain instances, the shaped abrasive particles can have acorner/midpoint differential thickness of at least 1.1, wherein thecorner/midpoint differential thickness (c/mΔt) is a measure of thethickness of the body at the midpoint divided by the thickness of atleast one corner. In certain embodiments, the corner/midpointdifferential thickness can be greater, such as at least about 1.2, atleast about 1.4, wherein the at least about 1.6, at least about 1.8, atleast about 2, at least about 2.2, at least about 2.4, at least about 3,or even at least about 4. Still, in one non-limiting embodiment, thecorner/midpoint differential thickness (c/mΔt) can be not greater thanabout 20, such as not greater than about 18, not greater than about 15,not greater than about 12, not greater than about 10, not greater thanabout 8, not greater than about 6, or even not greater than about 4. Itwill be appreciated that the shaped abrasive particles herein can have abody having a corner/midpoint differential thickness (c/mΔt) within arange between any of the minimum and maximum values noted above.

It will be appreciated that the above characteristics can be attributedto a batch of shaped abrasive particles. The batch can include a sampleof at least about 20 discrete shaped abrasive particles selected atrandom. Each of the discrete shaped abrasive particles of the sample canbe measured to determine average dimensions of midpoint thickness andcorner thickness of the sample that are representative of the batch.

FIG. 14C includes a cross-sectional illustration of a portion of theshaped abrasive particle of FIG. 14A. In particular, FIG. 14C includes across-sectional illustration of the shaped abrasive particle along axis1460, which is defined as an axis extending through the midpoint 1441and a midpoint 1442 of a side 1403 of the body 1401. In accordance withone embodiment, the body 1401 can have a greater thickness at a midpoint1441 of the body 1401 than a thickness at a midpoint edge 1442 of thebody 1401. Notably, the shaped abrasive particles can have anedge/midpoint differential thickness (e/mΔt) of at least 1.1, whereinthe edge/midpoint differential thickness is a measure of the thicknessof the body at the midpoint 1341 divided by the thickness of a sidesurface at the midpoint between two corners. In other embodiments, theedge/midpoint differential thickness (e/mΔt) can be greater, such as atleast about 1.2, at least about 1.4, wherein the at least about 1.6, atleast about 1.8, at least about 2, at least about 2.2, at least about2.4, at least about 3, or even at least about 4. Still, in onenon-limiting embodiment, the edge/midpoint differential thickness(e/mΔt) can be not greater than about 20, such as not greater than about18, not greater than about 15, not greater than about 12, not greaterthan about 10, not greater than about 8, not greater than about 6, oreven not greater than about 4. It will be appreciated that the shapedabrasive particles herein can have a body having an edge/midpointdifferential thickness (e/mΔt) within a range between any of the minimumand maximum values noted above.

It will be appreciated that the above characteristics can be attributedto a batch of shaped abrasive particles. The batch can include a sampleof at least about 20 discrete shaped abrasive particles selected atrandom. Each of the discrete shaped abrasive particles of the sample canbe measured to determine average dimensions of midpoint thickness andcorner thickness of the sample that are representative of the batch.

FIG. 15 includes an illustration of a shaped abrasive particle accordingto another embodiment. As depicted, the shaped abrasive particle 1500may include a body 1501 that may be formed according to an embodimentherein. Notably, the shaped abrasive particle may be formed from anextruded sheet via a punching process. The body 1501 can include acentral portion 1502 that extends along a longitudinal axis 1504. Afirst radial arm 1506 may extend outwardly from the central portion 1502along the length of the central portion 1502. A second radial arm 1508may extend outwardly from the central portion 1502 along the length ofthe central portion 1502. A third radial arm 1510 may extend outwardlyfrom the central portion 1502 along the length of the central portion1502. Moreover, a fourth radial arm 1512 may extend outwardly from thecentral portion 1502 along the length of the central portion 1502. Theradial arms 1506, 1508, 1510, and 1512 may be equally spaced around thecentral portion 1502 of the shaped abrasive particle 1500.

As shown in FIG. 15, the first radial arm 1506 may include a generallyarrow shaped distal end 1520. The second radial arm 1508 may include agenerally arrow shaped distal end 1522. The third radial arm 1510 mayinclude a generally arrow shaped distal end 1524. Further, the fourthradial arm 1512 may include a generally arrow shaped distal end 1526.

FIG. 15 also illustrates that the shaped abrasive particle 1500 may beformed with a first void 1530 between the first radial arm 1506 and thesecond radial arm 1508. A second void 1532 may be formed between thesecond radial arm 1508 and the third radial arm 1510. A third void 1534may also be formed between the third radial arm 1510 and the fourthradial arm 1512. Additionally, a fourth void 1536 may be formed betweenthe fourth radial arm 1512 and the first radial arm 1506.

FIGS. 16 and 17 include an illustration of a shaped abrasive particleaccording to another embodiment. As shown, the shaped abrasive particle1600 may include a body 1601 that has a generally cube-like shape. Itwill be appreciated that the shaped abrasive particle may be formed tohave other polyhedral shapes. The body 1601 may have a first end face1602 and a second end face 1604, a first lateral face 1606 extendingbetween the first end face 1602 and the second end face 1604, a secondlateral face 1608 extending between the first end face 1602 and thesecond end face 1604. Further, the body 1601 can have a third lateralface 1610 extending between the first end face 1602 and the second endface 1604, and a fourth lateral face 1612 extending between the firstend face 1602 and the second end face 1604.

As shown, the first end face 1602 and the second end face 1604 can beparallel to each other and separated by the lateral faces 1606, 1608,1610, and 1612, giving the body a cube-like structure. However, in aparticular aspect, the first end face 1602 can be rotated with respectto the second end face 1604 to establish a twist angle 1614. Inparticular instances, the shaped abrasive particle 1600 can be formedfrom the processes described herein, including sectioning a sheet, andmore particularly sectioning a sheet that has been torqued or twisted ina particular manner to impart a twist angle to the finally-formed shapedabrasive particle. In certain instances, the twist of the body 1601 canbe along one or more axes and define particular types of twist angles.For example, as illustrated in a top-down view of the body in FIG. 17looking down the longitudinal axis 1680 defining a length of the body1601 on the end face 1602 parallel to a plane defined by the lateralaxis 1681 extending along a dimension of width of the body 1601 and thevertical axis 1682 extending along a dimension of height of the body1601.

According to one embodiment, the body 1601 can have a longitudinal twistangle 1614 defining a twist in the body 1601 about the longitudinal axissuch that the end faces 1602 and 1604 are rotated relative to eachother. The twist angle 1614, as illustrated in FIG. 17 can be measuredas the angle between a tangent of a first edge 1622 and a second edge1624, wherein the first edge 1622 and second edge 1624 are joined by andshare a common edge 1626 extending longitudinally between two of thelateral faces (1610 and 1612). It will be appreciated that other shapedabrasive particles can be formed to have twist angles relative to thelateral axis, the vertical axis, and a combination thereof. Any suchtwist angles can have a value as described in the embodiments herein.

In a particular aspect, the twist angle 1614 can be at least about 1°.In other instances, the twist angle 1614 can be greater, such as atleast about 2°, at least about 5°, at least about 8°, at least about10°, at least about 12°, at least about 15°, at least about 18°, atleast about 20°, at least about 25°, at least about 30°, at least about40°, at least about 50°, at least about 60°, at least about 70°, atleast about 80°, or even at least about 90°. Still, according to certainembodiments, the twist angle 1614 can be not greater than about 360°,such as not greater than about 330°, such as not greater than about300°, not greater than about 270°, not greater than about 230°, notgreater than about 200°, or even not greater than about 180°. It will beappreciated that certain shaped abrasive particles can have a twistangle within a range between any of the minimum and maximum angles notedabove.

FIG. 18 includes a cross-sectional illustration of a coated abrasivearticle incorporating the abrasive particulate material in accordancewith an embodiment. As illustrated, the coated abrasive 1800 can includea substrate 1801 and a make coat 1803 overlying a surface of thesubstrate 1801. The coated abrasive 1800 can further include abrasiveparticulate material 1806. The abrasive particulate material can includea first type of shaped abrasive particle 1805, a second type of abrasiveparticulate material 1807 in the form of diluent abrasive particleshaving a random shape, which may not necessarily be shaped abrasiveparticles. The coated abrasive 1800 may further include size coat 1804overlying and bonded to the abrasive particulate material 1806 and themake coat 1804.

According to one embodiment, the substrate 1801 can include an organicmaterial, inorganic material, and a combination thereof. In certaininstances, the substrate 1801 can include a woven material. However, thesubstrate 1801 may be made of a non-woven material. Particularlysuitable substrate materials can include organic materials, includingpolymers, and particularly, polyester, polyurethane, polypropylene,polyimides such as KAPTON from DuPont, paper. Some suitable inorganicmaterials can include metals, metal alloys, and particularly, foils ofcopper, aluminum, steel, and a combination thereof.

The make coat 1803 can be applied to the surface of the substrate 1801in a single process, or alternatively, the abrasive particulatematerials 1806 can be combined with a make coat 1803 material andapplied as a mixture to the surface of the substrate 1801. Suitablematerials of the make coat 1803 can include organic materials,particularly polymeric materials, including for example, polyesters,epoxy resins, polyurethanes, polyamides, polyacrylates,polymethacrylates, poly vinyl chlorides, polyethylene, polysiloxane,silicones, cellulose acetates, nitrocellulose, natural rubber, starch,shellac, and mixtures thereof. In one embodiment, the make coat 1803 caninclude a polyester resin. The coated substrate can then be heated inorder to cure the resin and the abrasive particulate material to thesubstrate. In general, the coated substrate 1801 can be heated to atemperature of between about 100° C. to less than about 250° C. duringthis curing process.

The abrasive particulate material 1806 can include shaped abrasiveparticles according to embodiments herein. In particular instances, theabrasive particulate material 1806 may include different types of shapedabrasive particles. The different types of shaped abrasive particles candiffer from each other in composition, two-dimensional shape,three-dimensional shape, size, and a combination thereof as described inthe embodiments herein. As illustrated, the coated abrasive 1800 caninclude a shaped abrasive particle 1805 having a generally triangulartwo-dimensional shape.

The other type of abrasive particles 1807 can be diluent particlesdifferent than the shaped abrasive particles 1805. For example, thediluent particles can differ from the shaped abrasive particles 1805 incomposition, two-dimensional shape, three-dimensional shape, size, and acombination thereof. For example, the abrasive particles 1807 canrepresent conventional, crushed abrasive grit having random shapes. Theabrasive particles 1807 may have a median particle size less than themedian particle size of the shaped abrasive particles 1805.

After sufficiently forming the make coat 1803 with the abrasiveparticulate material 1806, the size coat 1804 can be formed to overlieand bond the abrasive particulate material 1806 in place. The size coat1804 can include an organic material, may be made essentially of apolymeric material, and notably, can use polyesters, epoxy resins,polyurethanes, polyamides, polyacrylates, polymethacrylates, poly vinylchlorides, polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and mixtures thereof.

FIG. 19 includes an illustration of a bonded abrasive articleincorporating the abrasive particulate material in accordance with anembodiment. As illustrated, the bonded abrasive 1900 can include a bondmaterial 1901, abrasive particulate material 1902 contained in the bondmaterial, and porosity 1908 within the bond material 1901. In particularinstances, the bond material 1901 can include an organic material,inorganic material, and a combination thereof. Suitable organicmaterials can include polymers, such as epoxies, resins, thermosets,thermoplastics, polyimides, polyamides, and a combination thereof.Certain suitable inorganic materials can include metals, metal alloys,vitreous phase materials, crystalline phase materials, ceramics, and acombination thereof.

In some instances, the abrasive particulate material 1902 of the bondedabrasive 1900 can include shaped abrasive particles 1903. In particularinstances, the shaped abrasive particles 1903 can be different types ofparticles, which can differ from each other in composition,two-dimensional shape, three-dimensional shape, size, and a combinationthereof as described in the embodiments herein. Alternatively, thebonded abrasive article can include a single type of shaped abrasiveparticle.

The bonded abrasive 1900 can include a type of abrasive particulatematerial 1907 representing diluent abrasive particles, which can differfrom the shaped abrasive particles 1903 in composition, two-dimensionalshape, three-dimensional shape, size, and a combination thereof.

The porosity 1908 of the bonded abrasive 1900 can be open porosity,closed porosity, and a combination thereof. The porosity 1908 may bepresent in a majority amount (vol %) based on the total volume of thebody of the bonded abrasive 1900. Alternatively, the porosity 1908 canbe present in a minor amount (vol %) based on the total volume of thebody of the bonded abrasive 1900. The bond material 1901 may be presentin a majority amount (vol %) based on the total volume of the body ofthe bonded abrasive 1900. Alternatively, the bond material 1901 can bepresent in a minor amount (vol %) based on the total volume of the bodyof the bonded abrasive 1900. Additionally, abrasive particulate material1902 can be present in a majority amount (vol %) based on the totalvolume of the body of the bonded abrasive 1900. Alternatively, theabrasive particulate material 1902 can be present in a minor amount (vol%) based on the total volume of the body of the bonded abrasive 1900.

FIG. 21 includes an illustration of a side view of a shaped abrasiveparticle according to an embodiment. As illustrated, the shaped abrasiveparticle 2100 can include a body 2101 including a first layer 2102 and asecond layer 2103 overlying the first layer 2102. According to anembodiment, the body 2101 can have layers 2102 and 2103 that arearranged in a stepped configuration relative to each other. A steppedconfiguration can be characterized by a degree of misorientation betweentwo or more portions (e.g., layers) of a body of a shaped abrasiveparticle. The degree of misorientation may be controlled orpredetermined by one or more processing parameters and may facilitate animproved deployment of the abrasive particles into an abrasive articleand performance of the abrasive article.

The stepped configuration may be defined by a lateral shift 2104, whichmay be defined as the greatest lateral distance 2107 between a firstedge 2105 of the first layer 2102 and a second edge 2106 of the secondlayer 2106. Notably, the body 2101 also demonstrates a steppedconfiguration 2108, wherein a portion of the second layer 2103 overhangsthe first layer 2102, however such a stepped configuration may notnecessarily define the lateral shift of the body 2101, since the lateralshift 2104 has a greater lateral distance 2107 as compared to thelateral distance of the stepped configuration 2108. Furthermore, asnoted in FIG. 20B, the lateral shift 2109 may be measured by thedistance 2110 between an edge of the first layer 2002 and an edge of thesecond layer 2003 in a direction toward a midpoint 2020 of the body 2001to make analysis of the lateral shift feasible from a top-view. Anyfeatures of the embodiments herein, including for example, lateral shiftmay be analyzed using suitable imaging software, including for example,ImageJ software.

According to one embodiment, the body 2101 can have a lateral shiftdefined by a lateral distance 2107 of at least about 1% of the length ofthe body 2101. In other embodiments, the lateral distance 2107 can begreater, such as at least about 2%, at least about 5%, at least about8%, at least about 10%, at least about 20%, at least about 25%, at leastabout 30%, or even at least about 50% of the length of the body 2101. Instill one non-limiting embodiment, the lateral distance 2107 can be notgreater than about 90%, such as not greater than about 80%, not greaterthan about 70%, not greater than about 60%, not greater than about 50%,not greater than about 40%, not greater than about 30%, or even notgreater than about 20% of the length of the body 2101.

It will be appreciated that any of the characteristics of theembodiments herein can be attributed to a batch of shaped abrasiveparticles. A batch of shaped abrasive particle can include, but need notnecessarily include, a group of shaped abrasive particles made throughthe same forming process. In yet another instance, a batch of shapedabrasive particles can be a group of shaped abrasive particles of anabrasive article, such as a fixed abrasive article, and moreparticularly, a coated abrasive article, which may be independent of aparticular forming method, but having one or more defining featurespresent in a particular population of the particles. For example, abatch of particles may include an amount of shaped abrasive particlessuitable for forming a commercial grade abrasive product, such as atleast about 20 lbs. of particles.

Moreover, any of the features of the embodiments herein (e.g., aspectratio, multiple portions, multiple layers, diffusion interfaces,difference in thickness, difference in two-dimensional shape, etc.) canbe part of a single particle, a median value from a sampling ofparticles of a batch, or an average value derived from analysis of asampling of particles from a batch. Unless stated explicitly, referenceherein to the characteristics can be considered reference to a medianvalue that is a based on a statistically significant value derived froma random sampling of suitable number of particles of a batch. Notably,for certain embodiments herein, the sample size can include at least 10,and more typically, at least 40 randomly selected particles from a batchof particles.

Any of the features described in the embodiments herein can representfeatures that are present in at least a portion of a batch of shapedabrasive particles. The portion may be a minority portion (e.g., lessthan 50% and any whole number integer between 1% and 49%) of the totalnumber of particles in a batch, a majority portion (e.g., 50% or greaterand any whole number integer between 50% and 99%) of the total number ofparticles of the batch, or even essentially all of the particles of abatch (e.g., between 99% and 100%). The provision of one or morefeatures of any shaped abrasive particle of a batch may facilitatealternative or improved deployment of the particles in an abrasivearticle and may further facilitate improved performance or use of theabrasive article.

A batch of particulate material can include a first portion including afirst type of shaped abrasive particle and a second portion including asecond type of shaped abrasive particle. The content of the firstportion and second portion within the batch may be controlled at leastin part based upon certain processing parameters. Provision of a batchhaving a first portion and a second portion may facilitate alternativeor improved deployment of the particles in an abrasive article and mayfurther facilitate improved performance or use of the abrasive article.

The first portion may include a plurality of shaped abrasive particles,wherein each of the particles of the first portion can havesubstantially the same features, such as a same two-dimensional shape, asame configuration of portions making substantially similar compositebodies (e.g., same number or orientation of layers), and the like. Thebatch may include various contents of the first portion. For example,the first portion may be present in a minority amount or majorityamount. In particular instances, the first portion may be present in anamount of at least about 1%, such as at least about 5%, at least about10%, at least about 20%, at least about 30%, at least about 40%, atleast about 50%, at least about 60%, or even at least about 70% for thetotal content of portions within the batch. Still, in anotherembodiment, the batch may include not greater than about 99%, such asnot greater than about 90%, not greater than about 80%, not greater thanabout 70%, not greater than about 60%, not greater than about 50%, notgreater than about 40%, not greater than about 30%, not greater thanabout 20%, not greater than about 10%, not greater than about 8%, notgreater than about 6%, or even not greater than about 4% of the totalportions within the batch. The batch can include a content of the firstportion within a range between any of the minimum and maximumpercentages noted above.

The second portion can include a plurality of shaped abrasive particles,wherein each of the shaped abrasive particles of the second portion canhave substantially the same type of two-dimensional shape. The secondportion can have one or more features of the embodiments herein, whichcan be distinct compared to the plurality of shaped abrasive particlesof the first portion. In certain instances, the batch may include alesser content of the second portion relative to the first portion, andmore particularly, may include a minority content of the second portionrelative to the total content of particles in the batch. For example,the batch may contain a particular content of the second portion,including for example, not greater than about 40%, such as not greaterthan about 30%, not greater than about 20%, not greater than about 10%,not greater than about 8%, not greater than about 6%, or even notgreater than about 4%. Still, in at least on non-limiting embodiment,the batch may contain at least about 0.5%, such as at least about 1%, atleast about 2%, at least about 3%, at least about 4%, at least about10%, at least about 15%, or even at least about 20% of the secondportion for the total content of portions within the batch. It will beappreciated that the batch can contain a content of the second portionwithin a range between any of the minimum and maximum percentages notedabove.

Still, in an alternative embodiment, the batch may include a greatercontent of the second portion relative to the first portion, and moreparticularly, can include a majority content of the second portion forthe total content of particles in the batch. For example, in at leastone embodiment, the batch may contain at least about 55%, such as atleast about 60% of the second portion for the total portions of thebatch.

In one particular embodiment, the batch can include a first portionincluding a plurality of shaped abrasive particles, wherein each of theparticles have a body including a first layer and a second layeroverlying the first layer. The batch may include a second portionincluding a plurality of shaped abrasive particles, wherein each of theparticles have a body including a first layer, a second layer overlyingthe first layer, and an intermediate layer disposed between the firstlayer and the second layer. It will be appreciated that the foregoingembodiment is one of a variety of exemplary batches that can include atleast first and second portions, wherein each of the portions include aplurality of shaped abrasive particles, and each of the particles of thedifferent portions have at least one feature distinct from each other.

It will be appreciated that the batch can include other portions,including for example a third portion, comprising a plurality of shapedabrasive particles having a third feature that can be distinct from thefeatures of the particles of the first and second portions. The batchmay include various contents of the third portion relative to the secondportion and first portion. The third portion may be present in aminority amount or majority amount. In particular instances, the thirdportion may be present in an amount of not greater than about 40%, suchas not greater than about 30%, not greater than about 20%, not greaterthan about 10%, not greater than about 8%, not greater than about 6%, oreven not greater than about 4% of the total portions within the batch.Still, in other embodiments the batch may include a minimum content ofthe third portion, such as at least about 1%, such as at least about 5%,at least about 10%, at least about 20%, at least about 30%, at leastabout 40%, or even at least about 50%. The batch can include a contentof the third portion within a range between any of the minimum andmaximum percentages noted above. Moreover, the batch may include acontent of diluent, randomly shaped abrasive particles, which may bepresent in an amount the same as any of the portions of the embodimentsherein.

EXAMPLE

A first mixture in the form of a gel is made including 35-46 wt %boehmite commercially from Sasol Corporation. The mixture also includeswater, and a minor content of nitric acid, and organic material. Thefirst mixture is printed into openings of a first screen havingequilateral triangular-shaped openings having a length of a side ofapproximately 1-2.5 mm, forming a first group of precursor shapedabrasive particles in the first screen.

A second mixture in the form of a gel is made using the first mixturewith an additive of approximately 1 wt % for a total weight of thesolids of a dopant precursor. The dopant precursor is acetate stabilizedcolloidal zirconia commercially available as Nyacol. A second screen isplaced over the first group of precursor shaped particles. The secondscreen has equilateral triangular-shaped openings having a length of aside of approximately 1-2.5 mm. The second mixture is printed into theopenings of the second screen and onto the surfaces of the first groupof precursor shaped abrasive particles. The particles are dried and thensintered at 1300° C. to 1400° C. for 15 minute to 1 hour in air.

Particles were formed according to Example 1 and subject to imaginganalysis. FIG. 22 includes a side view image of a shaped abrasiveparticle formed according to the embodiment of Example 1. Asillustrated, the body 2201 has a first layer 2202 and a second layer2203 overlying the first layer 2202. The layers 2202 and 2203 areoriented in a stepped configuration and define a lateral shift distanceof approximately 17% relative to the length of the body as measured bylength of the side of the second layer 2203 as shown in the image. Asignificant portion of the particles formed according to Example 1demonstrated this stepped configuration.

FIGS. 23A and 23B include images of the shaped abrasive particles madeaccording to Example 1. The shaped abrasive particle of FIG. 23A has abody 2301 including a first layer 2302 and a second layer 2303 overlyingthe first layer 2302. As shown, an elemental line scan was conducted atline 2300 across the thickness of the body 2301 to analyze the diffusionprofile of the zirconium-containing dopant material of the second layer2303 into the first layer 2302. Notably, within the second layer 2303,the content of the dopant as shown at 2304 is significantly different ascompared to the content of the dopant in the first layer 2302 as shownat 2305. In particular, the content of dopant in the second layer 2303is significantly greater than the content of dopant in the first layer2302.

The body 2301 includes a diffusion interface 2306 defined by the stepfunction difference in the concentration of the dopant between the firstlayer 2302 and the second layer 2302. While some diffusion of the dopantmaterial has occurred from the second layer 2303 into the first layer2302, the diffusion interface is evident based on the difference inzirconium content at 2304 in the second layer 2303 compared to thecontent of zirconium measured at 2305 in the first layer 2302.

The shaped abrasive particle of FIG. 23B has a body 2311 including afirst layer 2312 and a second layer 2313 overlying the first layer 2312.As shown, an elemental line scan was conducted at line 2310 across thethickness of the body 2311 to analyze the diffusion profile of thezirconium-containing dopant material of the second layer 2313 into thefirst layer 2312. Notably, within the second layer 2313, the content ofthe dopant as shown at 2314 is significantly different, and inparticular, significantly greater, as compared to the content of thedopant in the first layer 2312 as shown at 2315. Moreover, the body 2311has an evident diffusion interface 2316 defined by the step functiondifference in the concentration of the dopant between the first layer2312 and the second layer 2312. While some diffusion of the dopantmaterial has occurred from the second layer 2313 into the first layer2312, the diffusion interface 2316 is apparent based on the differencein zirconium content at 2314 in the second layer 2313 compared to thecontent of zirconium measured at 2315 in the first layer 2312.

The present application represents a departure from the state of theart. While the industry has recognized that shaped abrasive particlesmay be formed through processes such as molding and screen printing, theprocesses of the embodiments herein are distinct from such processes.Notably, the embodiments herein include a combination of processfeatures facilitating the formation of batches of shaped abrasiveparticle having particular features. Moreover, the shaped abrasiveparticles of the embodiments herein can have a particular combination offeatures distinct from other particles including, but not limited to,aspect ratio, composition, additives, two-dimensional shape,three-dimensional shape, stepped configuration, differenttwo-dimensional shapes, diffusion interfaces, difference in dopantconcentration for different portions, layers, and regions, and acombination thereof. And in fact, one or more such features are expectedto facilitate alternative deployments in abrasive articles, and further,may facilitate improved performance in the context of fixed abrasives,such as bonded abrasives or coated abrasives.

The above-disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Thus, to the maximum extentallowed by law, the scope of the present invention is to be determinedby the broadest permissible interpretation of the following claims andtheir equivalents, and shall not be restricted or limited by theforegoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description, various features may be groupedtogether or described in a single embodiment for the purpose ofstreamlining the disclosure. This disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description, witheach claim standing on its own as defining separately claimed subjectmatter.

What is claimed is:
 1. A particulate material comprising: a shaped abrasive particle having a body comprising: a first layer; a second layer overlying the first layer and comprising a second dopant; and wherein the first layer and the second layer are arranged in a stepped configuration with respect to each other, and wherein the stepped configuration is defined by a lateral shift of the first layer with respect to the second layer.
 2. The particulate material of claim 1, wherein the lateral shift comprises a lateral distance of at least about 1% of the total length of the body.
 3. The particulate material of claim 1, wherein the first layer comprises a first thickness and the second layer comprises a second thickness, and wherein the first thickness and the second thickness are different by at least about 5%.
 4. The particulate material of claim 1, wherein the first layer comprises a first thickness of at least about 5% of an average thickness of the body, and wherein the second layer comprises a second thickness of at least about 5% of an average thickness of the body.
 5. The particulate material of claim 1, wherein the second dopant is selected from the group consisting of alkali elements, alkaline earth elements, rare-earth elements, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), and a combination thereof.
 6. The particulate material of claim 1, wherein the second dopant comprises zirconium.
 7. The particulate material of claim 1, wherein the second dopant comprises zirconia, and wherein the second layer comprises a greater content of zirconia than a content of zirconia in the first layer.
 8. The particulate material of claim 1, wherein the first layer defines a first two-dimensional shape as viewed in a plane defined by a length and a width of the body selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
 9. The particulate material of claim 8, wherein the second layer defines a second two-dimensional shape as viewed in a plane defined by a length and a width of the body selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
 10. The particulate material of claim 9, wherein the second two-dimensional shape is different than the first two-dimensional shape.
 11. A particulate material comprising: a shaped abrasive particle having a body comprising: a first layer; a second layer overlying the first layer and comprising a second dopant, wherein the second dopant comprises zirconia, and wherein the second layer comprises a greater content of zirconia than a content of zirconia in the first layer; and wherein the first layer and the second layer are arranged in a stepped configuration with respect to each other.
 12. The particulate material of claim 11, wherein the stepped configuration is defined by a lateral shift of the first layer with respect to the second layer.
 13. The particulate material of claim 12, wherein the lateral shift comprises a lateral distance of at least about 1% of the total length of the body.
 14. The particulate material of claim 11, wherein the first layer comprises a first thickness and the second layer comprises a second thickness, and wherein the first thickness and the second thickness are different by at least about 5%.
 15. The particulate material of claim 11, wherein the first layer comprises a first thickness of at least about 5% of an average thickness of the body, and wherein the second layer comprises a second thickness of at least about 5% of an average thickness of the body.
 16. The particulate material of claim 11, wherein the first layer defines a first two-dimensional shape as viewed in a plane defined by a length and a width of the body selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
 17. The particulate material of claim 16, wherein the second layer defines a second two-dimensional shape as viewed in a plane defined by a length and a width of the body selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
 18. The particulate material of claim 17, wherein the second two-dimensional shape is different than the first two-dimensional shape.
 19. The particulate material of claim 1, wherein the body comprises an oxide.
 20. The particulate material of claim 11, wherein the body comprises an oxide. 